Insulated triple trough coil car

Abstract

A coil car has three parallel, longitudinally extending troughs—a central trough lying between two laterally outboard outer troughs. Each trough is shaped to cradle steel coils, or other similar loads, between its inwardly and downwardly sloping shoulder plates. The shoulder plates are lined with cushioning to buffer coils during loading or travel. The troughs are lined to permit warm coils to be carried. The car has coil stops to discourage longitudinal shifting of loaded coils. The coil stops have rollers to facilitate repositioning during loading, and a mid-span step and hand grabs to facilitate climbing over the coil stop by personnel walking along the trough structure.

Description

FIELD OF INVENTION

[0001] This invention relates to improvements in the structure of railway cars having multiple troughs for carrying metal coils, commonly referred to as coil cars, and more particularly to coil cars having insulation to permit the carriage of warm coils.

BACKGROUND OF THE INVENTION

[0002] Railroad coil cars are used to transport coiled materials, most typically coils of steel sheet. Coils can be carried with their coiling axes of rotation (that is, the axes of rotation about which the coils are wound) oriented longitudinally, that is, parallel to the rolling direction of the car. The coils are generally carried in a trough, or troughs, mounted on a railcar underframe. The troughs are generally V-shaped and have inwardly inclined surfaces that support the coil. The troughs are typically lined with wood decking to provide cushioning for the coils. When a coil sits in a trough, the circumference of the coil is tangent to the V at two points such that the coil is prevented from rolling.

[0003] A coil car may have single, double or triple longitudinally extending troughs. The use of multiple troughs allows any single car to carry either a load of large coils in the center trough or a load of relatively smaller diameter coils, or coils of various diameters such that lading more closely approaches maximum car capacity during a higher percentage of car operation. Additionally, some coil cars have been provided with trough assemblies that can be shifted to permit conversion between different trough modes. An example of a coil car that can be converted from a single to a double trough mode can be found in U.S. Pat. No. 3,291,072, issued to Cunningham on Dec. 13, 1966. Similarly, conversion of a coil car from a single or triple trough arrangement to a double trough mode is shown in U.S. Pat. No. 4,451,188, issued to Smith et al., on May 29, 1984. The general object is to versatility such that overall car utilisation is improved. Hence, the car is more economically attractive.

[0004] Historically, coil cars have been constructed on a flat car underframe having a through-center-sill, that is, a main center sill that runs from one end of the rail car to the other. In this type of car the center sill serves as the main structural member of the car and functions as the primary load path of the car both for longitudinal buff and draft loads from coupler to coupler, and for carrying the vertical load bending moment between the trucks. The trough structure, or bunk, is mounted on the flat car deck. In such a car the cross bearers carry loads into the main center sill. The side sills tend to be relatively small, and serve to tie the outboard ends of the cross bearers together. Conventionally, the center sill is box-shaped in cross-section. That is, it is rectangular and has a constant depth of section. The top and bottom flanges of the main center sill tend to be very heavy in such cars, since they are relied upon to carry the vertical bending load.

[0005] Alternatively, another way to construct a coil car having a triple trough arrangement employs a central trough supported by a main center sill and an array of laterally extending cross bearers and cross-ties that are angled upward and outward in a V-shape. At their distal end the cross bearers and cross-ties meet, and are tied together by, relatively small side sills in a manner generally similar to a flat car. A central trough extends longitudinally above the center sill with side troughs lying outboard of the central trough. The side troughs are formed using slanted decking and are mounted above the cross bearers at about the same height as the central trough relative to top of rail. In is arrangement the center sill is still relied upon to carry the great majority of the bending load.

[0006] Coil cars can also be fabricated as integrated structures. One way to do this is to employ a deep center sill, elevated side sills, and substantial cross bearers mounted in a V between the center sill and substantial, load bearing side sills. The cross bearers and trough sheets carry shear between the side sills and the center sill. In this way the structural skeleton of the car acts in the manner of a deep V-shaped channel with flanges at each toe, namely the side sills, and at the point of the V, namely the center sill. In this arrangement, under vertical bending loads, the side sills are in compression, and the main sill is in tension.

[0007] In the cases of either a V-shaped integrated structure, or even a traditional flat car based structure, it may be beneficial to employ a “fish belly” center sill. A fish belly center sill is a center sill that is relatively shallow over the trucks, and has a much deeper central portions in the longitudinal span between the trucks. It is advantageous to have a deeper section at mid-span where the bending moment due to vertical loads may tend to be greatest.

[0008] Another way to achieve a greater depth of effective section in an integrated structure, so that a higher sectional second moment of area is obtained, is to employ deep side sills, in a manner akin to a well car. The deep side sills act as longitudinal beams. A longitudinal cradle, namely the trough structure, is hung between the side sills. In this kind of car, the main longitudinal structural members are the side sills which carry the great majority of the bending load. The cradle itself may have a center sill to tie the cross bearers together at mid-span between the side sills. A center sill of modest proportions is sufficient for this purpose. The side sills carry the load back to main bolsters, and then into the draft gear mounted longitudinally outboard of each truck.

[0009] Where deep side sills are used, the minimum height of the bottom chord of the side sill is determined by the underframe portion of the design envelope prescribed by the AAR, such as for AAR plate B, plate C, or such other plate as may be applicable. At lower heights, the allowable width of the car diminishes, so the overall width of the car measured over the side sill bottom chords needs to be relatively narrow as sectional depth increases. Conversely, to accommodate the largest possible load width, it may tend to be desirable for the top chords of the side sills to be spread as far as possible within the allowable car width of 10′-8″. Thus it may be beneficial to locate the bottom chord closer to the car centerline than the top chord.

[0010] It may be desirable to be able to carry steel coils in a side-by-side arrangement. If three troughs are provided, it is advantageous for the center trough to be carried at a different height, relative to top of rail (TOR), than the outboard, or side, troughs. This may be beneficial for at least several reasons.

[0011] First, the total width of lading that can be carried by a coil car at one time is limited by the allowable car width envelope. If three identically sized coils are mounted such that the axes of the coils are carried at the same height relative to top of rail, then the sum of the diameters of the coils, plus the necessary clearance between coils, is limited by the maximum allowable coil car lading width. However, if the coiling axis of rotation of one coil is higher than an adjacent coil of equal or lesser diameter, then it may be possible to carry the coils in a partially encroaching, or overlapping, arrangement. That is, a greater sum of diameters may be accommodated than would otherwise be possible within the nominal maximum loading width. As a result, lading can include a combination of larger coils than might otherwise be possible, thus tending to improve car capacity utilisation.

[0012] Second, it is desirable that the point of maximum width of the load be carried at a height that is greater than the height of the uppermost extremity of the top chord members of the side sills. Once again, the advantage of this is that, generally, this will allow the vertical projection of the outboard coil to encroach more closely to the inner edge of the top chord, and so permit a larger coil to be carried in the outboard trough. This condition may be reached when the car is carrying two coils in excess of 40 inches in diameter side by side, with the central trough either empty, or carrying a relatively small coil, such as a coil of rather less than 30 inches in diameter. Since the second moment of area of the primary load bearing structure varies strongly with the depth of section, it if better for the side sill top chord to be carried at a relatively high level. Since the height of the top chord is related to the height of the outboard trough, an increase in elevation of the outboard trough by even a few inches is advantageous.

[0013] Third, in terms of car versatility, it is advantageous to be able to carry a variety of loads, whether a single very large coil in the central trough, two medium sized coils side-by-side in the outside troughs, or three somewhat smaller coils in each of three troughs. In general, the larger the central trough, the smaller the outboard troughs. If the outboard troughs are raised relative to the central trough, the overall trough capacity, and hence car versatility, will be increased. That is, a car with a central trough capable of accommodating a 74 inch coil, may only be able to accommodate 36 inch coils in the outboard troughs when the central trough is empty if the troughs are all carried at the same height, However, if the outboard troughs are carried at a higher level, then it may be possible to carry outboard coils of greater diameter, such as 44 or 48 inches, then the central trough is empty.

[0014] Reference is made herein to troughs being carried at the same, or different, heights relative to top of rail, commonly on an assumption of troughs of generally similar geometry. For the purposes of this description, each of the troughs has planar sloped side sheets. The planes of the opposed side sheets meet at some line of intersection parallel to the longitudinal center line of the car, the line of intersection lying at some height below the flat bottom of the valley of the trough. In structural terms, the difference in the height at which one trough is carried relative to another trough can be take by comparison of the heights of the flat bottoms of the valley, since the bottom height may tend to be defined by the upper flange of a longitudinally extending structural member.

[0015] Reference cap also be made to the height at which the centerlines of coils of the same size would lie for the various troughs. This is not a function of the height of the bottom of the valley, but rather of the height of the line of intersection of the planes of the slope sheets (assuming them to be planar), and the angle of the slope sheets. Once the angle of slope has been chosen, the difference in height of the flat bottom of the valley relative to the line of intersection of the planes is determined by the minimum diameter of coil to be carried, which will, with allowance for clearance, fix the width of the flat bottom. For troughs having the same angle of slope and the same bottom height, a narrow bottom will force a coil to be carried relatively higher than a wide bottom. Similarly, for bottoms of the same height and width, a steep slope will force a coil to be carried higher than a shallow slope.

[0016] The slope of the trough is an important design parameter. Whether for single or multiple trough cars, it is generally desirable that a coil not be able to escape from the trough during cornering. One standard is that a coil should not escape under a 0.45 g lateral load as a condition for general interchange service. This implies a trough slope of about 24.2 degrees measured from the horizontal. At least one rail road company has indicated that a slope of 23 degrees is acceptable for its purposes. It is also desirable for the troughs to have some allowance for lateral tilting or swaying of the cars during lateral loading, such as 2 or 3 degrees. This implies a desirable trough angle of about 27 degrees, (namely, 24 plus 3). Trough width is a function of the chord length between the points of tangency of the largest coil to be carried to the opposed trough sheets. Consequently, as the trough slope angle decreases, the trout width decreases. Similarly, as slope angle increases, the trough becomes wider. However, as noted above, the sum of the widths of the troughs is limited by the plate B envelope, less the widths of the side sills and a clearance dimension between the side sills and the coils, and between adjacent coils.

[0017] For trough width maximisation, it is advantageous for the side sills to be carried close to the design envelope lateral boundaries. For interchangeable service, the lateral boundaries are defined by AAR plate B, with a width of 128 inches. In the past, coil cars have carried walkways outboard of the side sills of the trough cradles, It is advantageous not to have walkways that would extend beyond the plate B limit. One inventor has suggested using folding walkways that can be moved to a retracted position within the side sills. It would be advantageous to employ fixed walkways that do not require moving mechanisms.

[0018] Another railroad requirement has been for a restraining device, called a coil stop, to prevent longitudinal displacement of the coils during operation. Typically, a coil stop is a transversely oriented beam, or movable bulkhead, located in position across the trough after a coil has been loaded, The coil stop extends between the side sills and can be moved to a location near to a seated coil. The coil stop is then releasably, or removably anchored, typically with pins that locate in perforated strips mounted to the side sills. Shims are then inserted between the coil stop and the coil to give a snug fit. One design criterion suggests that the restraining device bear upon the coil at a height that is at least as high as the horizontal chord that subtends an arc of 108 degrees of the largest coil the trough is capable of carrying.

[0019] It is possible to use a coil stop bar retaining strip that extending laterally inboard of the side sill. However, it is generally desirable to trim the coil stop engagement strip back to increase the capacity of the outboard troughs. To this end, alternative embodiments of coil stop are described. In one embodiment, a horizontal pin is used to engage a strip mounted to a side web of the top chord of the side sill. In another embodiment vertical pins of the coil stop engage perforations in a horizontal strip placed within the vertical profile of the top chord.

[0020] Since coil stops are relatively heavy, it would be advantageous to provide a coil stop that is deigned to be moved more easily from place to place along the troughs of the car. It would be advantageous to employ rollers, or a slider, for this purpose. Ease of adjustment can also be enhanced by reducing the weight of the coil stop, such as by removing material from the horizontal coil stop web.

[0021] When outboard troughs are used, as in a triple trough arrangement, it is advantageous for a longitudinal stringer to tie adjacent cross bearers together along the spine, or groin, of the outboard troughs. Where the cross bearer has a web and an upper flange defining the slope of the trough sheets, the stringer, such as a hollow section, can be located in a relief formed in the cross bearer web. The bottom of the trough so formed may also provide a walkway space. When the bottom of the trough is used as a walkway, it may be advantageous for the coil stop to be provided with climbing means, such as a step, or stile, and hand grabs.

[0022] In some instances it may be desired to carry coils that are hotter than room temperature. A coil of steel can be formed by reeling hot rolled sheet. The coil may leave the rolling mill at a very high temperature at which the steel is still glowing, and may have to be cooled for a significant period of time to reach temperatures at which it can be handled for railway transport purposes. A heavy coil can require a several hours of cooling before if falls to a temperature of 500-600 F. and can be moved, and may take longer still to reach a temperature below 150 F. Depending on the length and nature of the journey, it may be desirable to be able to move a coil while it is still relatively warm. That is, rather than sitting as inventory at rolling mill, some of the cooling time can include time spent in transit to the next processing operation. It may be that the coils can be loaded in coil cars and shunted at the mill to a location that will not impede further coil production, and then left to sit until fully cooled to a desired temperature. Alternatively, for short journeys and subsequent operations that require re-heating of the coil, there may be an energy saving by delivering the coil in a warm condition, rather than cooled to ambient temperatures.

[0023] As the coils cool, they will develop a temperature gradient, being relatively cooler on the outer circumference of the roil and relatively warmer on the inner circumference surface at the internal bore of the coil (i.e., at the donut-hole surface). Warm in this context is still quite hot as compared to ambient temperatures, and may entail an internal bore surface temperature of the order of 500 or 600 F. It is possible that more severe temperatures may be encountered in service.

[0024] Carriage of hot rolls, i.e., hot coils, requires a suitable car. First, the car must be able to accommodate a warm coil, and second the presence of a warm coil, or, coils, in the car should tend not to impair car operation. For example, brake fittings or hydraulic fittings should not tend to be unduly adversely affected . It is also undesirable for portions of the railcar body to become unduly hot to touch. In general then, it is desirable to discourage heat transfer from the coils into the body of the railcar.

[0025] Given that the principle path for heat transfer by conduction into the structure of the rail car body is through the points of contact, namely the points of tangency of the coils with the trough slope sheets, one way to deter heat loss through the car structure is to insulate the slope sheets. While the wood planking used as cushioning provides some insulation value, it has the disadvantage of being flammable at temperatures that are too low to provide a fully satisfactory operating range. Further, if the slope sheets of the trough are to be insulated, then the manner of insulation must be such as to permit the heavy weight of the steel coils to continue to be supported. To this end, insulating material, such as a thermally insulating ceramic or ceramic-like material can be placed over the oaken baulks that customarily provide a cushioning in the trough for the coils.

[0026] A ceramic, or ceramic like material, may tend to have suitable thermal insulation properties and a relatively high crush strength suitable for supporting the weight of a coil. Ceramics, or ceramic-like materials, may not tend to perform well if subject to abuse or accidental damage from impact loads. A steel load spreader plate, or liner, can be placed over the insulation material to spread the load and to reduce the tendency of the coils to crack or crush a ceramic or ceramic-like thermal insulation substrate, given the relatively high local stress concentration that would otherwise be observed at the points of tangent contact of the coil with the slope sheets of the trough, and given the possibility of accidental damage during coil handling operations.

[0027] Further, the present inventors have observed that, in addition to heat loss through the floor of the trough, there is significant heating of the end bulkheads. When large warm, or hot, coils are placed over the trucks, they tend to be placed in a position abutting the end bulkheads, such that the end bulkheads perform the function of fixed position coil stops. As such, the heat transfer from the coils to the end bulkheads can be quite high. For example, in one test of a single trough coil car the external end bulkhead temperature was observed to be in excess of 200 F. when a steel coil at over 500 F. was placed against the inside face of the bulkhead. It would be desirable to have a lower external surface temperature.

[0028] Furthermore, both the end bulkheads and the coil stops provided to discourage longitudinal motion of the coils once loaded, are customarily provided with pads suitable for snug placement against the end face of the coil. Recently these pads have been made of plastic materials, such as high density nylon. When hot coils are used, it is desirable that materials that melt, char or burn relatively easily, be supplanted by more fire resistant materials. More generally, the sides of the coil stop and the faces of the end bulkheads are most advantageously suited to high temperature operation (i.e., to about 600 F., if not more).

[0029] The inventors have also noted that when an insulated floor is used, it is possible to dispense with the wooden bulks, or planks previously used. That is, rather than resting upon the wooden members, the thermally insulating ceramic or ceramic-like material are permitted to lie directly on the deck plates. Should an excessively hot coil be placed in the trough such that the temperature on the underside of the insulating material should approach, or reach, the combustion temperature of the wood, the removal of wood from underneath the insulating panel removes an element that might otherwise char or burn.

SUMMARY OF THE INVENTION

[0030] In an aspect of the invention there is a railroad coil car having a length and a width. The coil car has a pair of first and second end structures each mountable upon a rail car truck. The coil car has a pair of side sills extending between the end structures. There is a trough structure for carrying coils mounted between the side sills. Each of the side sills has a top chord, a bottom chord and intermediate structure joining the top and bottom chords. The coil car has a greater width measured across the top chords of the side sills than across the bottom chords of the side sills.

[0031] In an additional feature of that aspect of the invention, the intermediate structure of each of the side sills includes a web extending between the top and bottom chords, and is inclined at an angle from vertical. In another additional feature, a center sill extends longitudinally beneath the trough structure and a set of cross bearers extends from the center sill to each of the side sills. In still another additional feature, the coil car further comprises a longitudinal structural member mounted to the cross bearers intermediate the center sill and each of the side sills. In a further additional feature of that aspect of the invention, the coil car has a plurality of longitudinal troughs, one of the plurality of troughs being mounted above each of the longitudinal structural members. In a still further feature, the trough structure is a triple trough structure having three longitudinally extending parallel troughs. In another additional feature, a set of cross members extend between the side sills, and the trough structure is supported by the set of cross members. In still another additional feature, the trough structure includes a plurality of longitudinally extending troughs mounted parallel to each other. In yet another additional feature the coil car has at least one longitudinally extending structural member mounted to bridge the cross members intermediate the side sills. In still yet another additional feature, one of the troughs is located above the longitudinally extending structural member. In a further additional feature, the car has at least two troughs and at least two longitudinally extending structural members mounted to bridge the cross members intermediate the side sills. One of the troughs is located above one of the longitudinally extending structural members and another of the troughs is located above another of the longitudinally extending structural members. In still a further additional feature, one of the troughs is mounted higher than another relative to top of rail.

[0032] In another additional feature each of the side sills has a pair of end portions and a medial portion between the end portions. Each of the end portions has a depth of section and the medial portion has a depth of section. The depth of section of the medial portion is greater than the depth of section of the end portions.

[0033] In another aspect of the invention, there is a railroad coil car having a length and a width. The coil car has a pair of first and second end structures each mounted upon a rail car truck. A pair of side sills extend between the end structures. A trough structure is mounted between the side sills. The trough structure includes at least two longitudinally extending parallel troughs. The side sills each have first and second end portions and a medial portion located between the first and second end portions. The medial portion has a greater depth of section than the end portions.

[0034] In an additional feature of that aspect of the invention, one of the troughs is mounted higher than another relative to top of rail. In another additional feature of that aspect of the invention, a set of cross members extend between the side sills, and the troughs are supported by the cross members intermediate the side sills. In still another additional feature of that aspect of the invention, at least one longitudinally extending structural member is mounted to bridge the cross members. In still yet another additional feature of that aspect of the invention, at least one of the troughs is centered on one of the longitudinally extending structural members.

[0035] In another additional feature of that aspect of the invention, the coil car has at least one longitudinal stringer mounted to the cross bearers intermediate the center sill and one of the side sills. In still another additional feature of that aspect of the invention, one of the troughs is centered on the stringer.

[0036] In yet another additional feature of that aspect of the invention, a first of the troughs has first and second opposed inclined flanks for cradling a coil. Each of the first and second flanks of the first trough lies in a plane. The planes intersect at a first line of intersection. A second of the troughs has first and second opposed inclined flanks for cradling a coil. Each of the first and second inclined flanks of the second trough lies in a plane. The planes intersect as a second line of intersection. The first line of intersection lies farther from top of rail than the second line of intersection.

[0037] In another aspect of the invention, there is a railroad coil car, having a length and a width. The coil car has a pair of first and second end structures each mounted upon a railcar truck. The coil car has a pair of first and second side sills extending between the end structures. Each of the side sills has a top chord, a bottom chord, and a web extending between the top chord and the bottom chord. A trough structure is mounted between the side sills. The trough structure includes at least first and second longitudinally oriented parallel troughs in which coils can be carried. The bottom chords of the side sills are mounted at a level lower than the trough structure relative to top of rail.

[0038] In still another additional feature, a longitudinally extending center sill is mounted between the side sills. A set of cross bearers extend between the center sill and the side sills. The trough structure is carried above the center sill and the cross bearers. In yet another additional feature, the center sill has a bottom flange, and the bottom flange of the center sill is located at a height at least as high above top of rail as the bottom chords of the side sills.

[0039] In still yet another additional feature, a first longitudinally extending structural member is mounted to bridge the cross bearers intermediate the center sill and the first side sill. A second longitudinally extending structural member is mounted to bridge the cross bearers intermediate the center sill and the second side sill. A first trough is mounted to the first longitudinally extending structural member and a second trough is mounted to the second longitudinally extending structural member.

[0040] In another aspect of the invention, there is a triple trough railroad coil car having a fish belly center sill.

[0041] In an additional feature of that aspect of the invention, the fish belly center sill has a camber in an unloaded condition of the triple trough railroad car. The center sill has a mid span clearance above top of rail that is greater than a clearance of the center sill above top of rail at a location away from mid-span.

[0042] In another additional feature, the fish belly center sill has a pair of shallow depth of section end portions and a central portion of greater depth of section therebetween. The central portion is of constant depth of section. In an alternative feature, the fish belly center sill has a pair of ends having a shallow depth of section and a central portion extending between the ends. The central portion has a variable depth of section. In another alternative feature, the central portion has a maximum depth of section at mid-span between the ends.

[0043] In still yet another additional feature, the triple trough includes a pair of side troughs and a center trough arranged therebetween. The pair of side troughs and the center trough extend lengthwise of the fish belly center sill. One of the troughs is carried lower relative to top of rail than the others. In another additional feature, the center trough is carried lower relative to top rail than the pair of side troughs.

[0044] In another aspect of the invention, there is a railroad coil car having a pair of ends mountable on spaced apart railcar trucks. The coil car has a length and a width. A center sill extends between the ends. The center sill has end portions and a central portion intermediate the end portions. The central portion has a greater depth of section than the end portions. A plurality of longitudinally extend troughs supported by the center sill.

[0045] In yet another additional feature of that aspect of the invention, the central trough can carry a coil of a first maximum diameter and each of the side troughs can carry a coil of a second maximum diameter different from the first maximum diameter. In still yet another additional feature, the first maximum diameter is greater than the second maximum diameter.

[0046] In another additional feature, a pair of longitudinally extending side sills mount outboard and upwardly of the center sill. In still another additional feature, the coil car has shear transfer members attached to the side sills and extending to the center sill whereby the center sill and the side sills act as an integrated structure having a second moment of area greater than the sum of the individual second moments of area of the center sill and the side sills.

[0047] In an alternative aspect of the invention there is a triple trough coil car having a center sill mounted upon a pair of first and second spaced apart rail car trucks for rolling motion in a longitudinal rolling direction. A trough structure is mounted above, and supported by, the center sill. The trough structure includes a first longitudinally extending trough mounted centrally above the center sill, and second and third longitudinally extending troughs mounted parallel to, and to either side of, the first longitudinally extending trough. The center sill has a first portion mounted over the first truck, a second portion mounted over the second truck, and a third portion extending between the first and second portions. The first, second and third portions of said center sill each have a depth of section. The depth of section of the third portion being greater than the depths of section of the first and second portions.

[0048] In another aspect of the invention, there is a coil car having a walkway mounted within the trough structure to facilitate movement of personnel along the car, whether for adjusting the coil stops or for cleaning and maintaining the car. That is to say, in that aspect of the invention there is a rail road coil car. It has a trough structure supported for carriage by rail car trucks for travel in a longitudinal rolling direction. The trough structure has a walkway mounted therewithin.

[0049] In a further feature of that aspect of the invention, the trough structure includes a first trough. The first trough is longitudinally oriented, and the walkway is oriented longitudinally within the first trough. In another feature, the first trough has a pair of first and second slope sheets defining opposed flanks of the first trough. The first trough has a valley bottom between the flanks, and the walkway extending along the valley bottom. In an additional feature, tread plates are mounted along the walkway. In another feature, the rail road coil car has a longitudinal structural member defining the valley bottom. In still another feature, the longitudinal structural member is a longitudinal center sill.

[0050] In a further feature, the rail road coil car includes a center sill and cross bearers extending laterally from the center sill. The cross bearers support the trough structure. The longitudinal structural member is a stringer mounted to the cross bearers. The longitudinal stringer lies laterally outboard to one side of the center sill. In another feature, the stringer is a first stringer, and the rail road car includes a second trough parallel to the first trough. The second trough has a second valley bottom lying over a second longitudinal stringer mounted to the cross bearers along the second valley bottom. In another additional feature the first and second stringers are located symmetrically to either side of the center sill. In still another feature, a third trough is mounted over the center sill parallel to the first and second troughs.

[0051] In a further feature, the trough structure includes a second trough extending parallel to the first trough, the second trough having third and fourth slope sheets defining opposed flanks of the second trough, the second trough having a valley bottom between the flanks thereof, and the second trough having a second walkway extending along the valley bottom thereof. In another feature, the rail road car has first and second side sills bounding the trough structure, and the walkway is located within the trough structure at a location between the side sills.

[0052] In another feature, the rail road coil car has structure defining a cover interface to which a coil car cover can be mounted, the interface defining a boundary to a region of the coil car sheltered when a cover is mounted to the cover interface, and the walkway lies within the boundary. In an additional feature, the rail road coil car includes a rail car body, the trough structure is part of the rail car body, and the rail road coil car includes a cover for sheltering coils carried in the trough structure, the cover being movable to permit loading of the coil car, the cover having a footprint mating with the rail car body, and the walkway falls within the footprint of the cover. In that additional feature, the rail car body includes first and second side sills extending longitudinally along opposite sides of the trough structure, and the cover seats on the side sills. In a further additional feature, the side sills each have a top chord, and the cover seats on the top chords of the side sills.

[0053] In another feature, the coil car has at least one movable coil stop mounted thereto, the coil stop being co-operable with the trough structure to accommodate coils of different thickness in the trough structure. In an additional feature, the walkway provides access to the coil stop. In another additional feature, the coil stop is mounted transversely relative to the walkway.

[0054] In a further additional feature of the invention, the coil car falls within a design envelope width limit of 128 inches. The trough structure includes first, second and third troughs, the first second and third troughs being parallel and extending in the longitudinal direction. First and second side sills extend longitudinally along opposite sides of the trough structure. The side sills include respective first and second top chord members. At least a portion of each of the respective first and second top chord members lies within 2 inches of the design envelope width limit.

[0055] In another aspect of the invention, there is a rail road coil car. It has a trough structure supported by rail car trucks for rolling motion in a longitudinal direction. The trough structure includes first, second and third troughs, the troughs being parallel and extending in the longitudinal direction. At least one of the first, second and third troughs has a pair of opposed slope sheets, each of the pair being inclined at least 23 degrees from horizontal. The first trough lies between the second and third troughs, The first trough has a capacity to accommodate a coil up to 84 inches in diameter and the second trough has a capacity to accommodate a coil up to 48 inches in diameter.

[0056] In an additional feature of that aspect of the invention, all of the first, the second, and the third troughs have respective pairs of opposed slope sheets, and all of the slope sheets of the respective pairs are inclined at least 23 degrees from horizontal. In another feature, the coil car falls within a design envelope defined by AAR Plate B; the trough structure is carried between longitudinally extending first and second side sills; each of the side sills has a top chord, and a portion of each of the top chords lies within 2 inches of car width limits of AAR Plate B.

[0057] In another feature each of the pair of opposed slope sheets is inclined at an angle lying in the range of between 23 and 29 degrees from horizontal. In an additional feature, each of the pair of opposed slope sheets is inclined at an angle lying in the range of between 24 and 28 degrees from horizontal. In a most preferred feature, each of the pair of opposed slope sheets is inclined at an angle of 27 degrees from horizontal.

[0058] In another feature, all of the first, the second, and the third troughs have respective pairs of opposed slope sheets, and all of the slope sheets of the respective pairs are inclined at an angle lying in the range of 24 to 28 degrees from horizontal. In yet another feature each of the first, second, and third troughs has a valley bottom, and the valley bottom of the first trough lies at a lower height above top of rail than the valley bottoms of the second and third troughs.

[0059] In another aspect of the invention, there is a coil stop for a rail road coil car. The coil car has a trough structure in which to carry coils. The coil stop has a beam member for spanning the trough structure. The beam member has a first end, a second end, and a medial portion extending between the first and second ends. The coil stop has a step mounted on the beam member between the first and second ends to facilitate climbing over the coil stop.

[0060] In a feature of that aspect of the invention, the step includes a tread plate mounted upon the beam. In another feature, the step is mounted centrally on the beam. In a further feature, a hand grab is mounted to the beam adjacent to the step. In an alternative, a pair of first and second hand grabs are mounted to either side of the step. In an additional feature, the hand grab is an upwardly extending hand rung.

[0061] In still another additional feature, the beam includes a horizontal web, and the step is mounted to the horizontal web. In an additional feature, the horizontal web has lightening holes defined herein. In another feature, at least one of the first and second ends has an indexing member mounted thereto for engagement with the coil car. In still another feature the coil stop includes rollers mounted at the first and second ends therefor for facilitating positioning of the coil stop in the trough structure of the rail car.

[0062] In another aspect of the invention there is a coil stop for a rail road coil car. The coil car has a trough structure in which to carry coils. The coil stop includes a beam member for spanning the trough structure. The beam member has a first end, a second end, and a medial portion extending between the first and second ends. The coil stop has rollers mounted at the first and second ends to facilitate positioning of the coil stop relative to the trough structure. In a further feature, the coil stop has indexing members mounted at the first and second ends of the beam member. The indexing members are engageable to maintain the coil stop in a fixed position relative to the trough structure. In an additional feature, the coil stop has attachment means mounted at the first and second ends of the beam by which to secure the coil stop in a fixed position relative to the trough structure.

[0063] In a further aspect of the invention, there is a rail road coil car having a rail car body supported by rail car trucks for rolling motion in a longitudinal direction. The rail car body including a trough structure for carrying coils, and at least one coil stop for restraining coils loaded in the trough structure. The coil stop is movable along the trough structure. A trackway is mounted to the body for guiding the coil stop along the trough structure. The coil stop has fittings engaged with the trackway. The fittings and the trackway are co-operable to permit motion of the coil stop along the trough structure.

[0064] In an additional feature of that aspect of the invention, the trough structure includes a first longitudinally oriented trough. The rail car body includes first and second side sills extending along the trough structure, and the trackway is mounted to the side sills. In a further additional feature, the trackway includes a first portion mounted to the first side sill and a second portion mounted to the second side sill, and the coil stop has a beam member spanning the trough. The beam member has a first end mounted to the first side sill and a second end mounted to the second side sill.

[0065] In another additional feature, the coil stop includes a beam member for spanning the trough structure. The beam member has a first end, a second end, and a medial portion extending between the first and second ends. The coil stop has a step mounted on the beam member between the first and second ends, whereby persons walking along the trough structure can more easily climb over the coil stop.

[0066] In an additional feature of that additional feature, the step includes a tread plate mounted upon the beam. The step is mounted centrally on the beam, and a hand grab is mounted to the beam adjacent to the step. Alternatively, a pair of first and second hand grabs is mounted to either side of the step. In an additional feature, the hand grab is an upwardly extending hand rung.

[0067] In another feature, the coil stop includes a beam member for spanning the trough structure, the beam member having a first end, a second end, and a medial portion extending between the first and second ends. The body has at least a first indexing fitting mounted thereto. At least one of the first and second ends has a second indexing member mounted thereto. The second indexing member is co-operable with the first indexing member to maintain the coil stop in a fixed position relative to the trough structure. In still another feature, the coil stop includes rollers mounted at the first and second ends therefor for facilitating positioning of the coil stop in the trough structure of the rail car.

[0068] In another aspect of the invention, there is a coil stop for a coil car having a trough structure in which to carry coils. The coil stop includes a beam member for spanning the trough structure. The beam member has a first end, a second end, and a medial portion extending between the first and second ends. The coil stop has a hand grab mounted on the beam member between the first and second ends, whereby to facilitate climbing over the coil stop by persons walking along the trough structure.

[0069] In another aspect of the invention there is a rail road coil car having a trough structure supported by railcar trucks for rolling motion in a longitudinal direction. The trough structure includes first, second and third longitudinally aligned, side-by-side troughs. Each of the first second and third troughs has deck sheeting for carrying coils loaded in the troughs. At least one of the troughs has a thermally insulative material mounted above the respective deck sheeting therof.

[0070] In an additional feature of that aspect of the invention, the trough structure includes laterally extending end walls, and the end walls have thermally insulative material mounted thereto. In another additional feature, the end bulkheads each have a face oriented inwardly toward the trough, and the thermal insulation is mounted to the inwardly oriented face. In a further feature, a liner is mounted to the thermal insulation material, the liner being mounted to face coils carried in the trough structure. In still another feature, the thermal insulation material is mounted between the inwardly oriented face of the bulkhead and a wear plate.

[0071] In a still further feature, the thermal insulation material mounted to the slope sheets is overlain by a liner. In an additional feature of that additional feature, the thermal insulation material mounted to the slope sheets overlies wooden planking. In a still further feature, the thermal insulation material mounted to the slope sheets is in direct contact with the slope sheets. In still another feature the thermal insulation material meets the slope sheet on a planar interface free of intervening layers. In a yet further feature, the thermal insulation material is non-flammable to at least 600 F.

[0072] In another aspect of the invention, there is a triple trough rail road coil car having a trough structure mounted on rail car trucks for rolling operation in a longitudinal direction. The trough structure includes first, second and third side-by-side troughs. At least one of the troughs has a pair of opposed inclined slope sheets co-operable to cradle a coil. The slope sheets have non-flammable thermal insulating materials mounted directly thereto.

[0073] In an additional feature of that aspect of the invention, the thermal insulation material is operable at temperatures at least as high as 600 F. In another feature, the trough structure includes a pair of transversely mounted walls defining end bulkheads of the trough structure, and the end bulkheads also have thermal insulation mounted thereto. In still another feature the thermal insulation mounted to the slope sheets is overlain by a load bearing liner. In yet another feature, the trough structure includes a pair of transversely mounted walls defining end bulkheads of the trough structure, the end bulkheads alto having thermal insulation mounted thereto, and the thermal insulation of each of the end bulkheads is shielded by a wear plate. In another feature, the thermal insulation mounted to the slope sheets is operable to at least 600 F., and the thermal insulation mounted to the end bulkheads is also operable to at least 600 F.

[0074] In another aspect of the invention, there is a triple trough rail road coil car having a trough structure carried upon rail car trucks in a longitudinal rolling direction. The trough structure includes three side-by side troughs. At least a first of the troughs has a pair of opposed inclined slope sheets, and a pair of transversely extending end walls defining end bulkheads of the first trough. The slope sheets are each provided with a layer non-flammable structural thermal insulation mounted thereabove. The non-flammable insulation is overlain by a wear plate. Each of the end bulkheads has a layer of non-flammable insulation material mounted thereto facing inwardly into the trough. The layer of insulation material mounted to each of the end bulkheads is shielded by another wear plate.

[0075] In an additional feature of that aspect of the invention, the insulation material above the slope sheets, and the insulation material mounted to the end bulkheads being non-flammable to at least 600 F. In another feature the non-flammable insulation material lies directly in contact with the slope sheets. In still another feature the trough structure is supported by a plurality of cross members mounted along the car, and the trough structure is stung between a pair of side sills whose depth of section exceeds that of the trough.

[0076] In another aspect of the invention there is a triple trough rail road coil car having a trough structure mounted on rail car trucks for rolling operation in a longitudinal direction. The trough structure includes three side-by-side troughs. At least one of the troughs has a pair of opposed inclined slope sheets co-operable to cradle a coil, and a pair of end walls mounted transversely relative to the slope sheets to define end bulkheads of the trough structure. The and bulkheads have thermal insulating materials mounted thereto.

[0077] In another aspect of the invention, there is a rail road coil car, having a length and a width. The coil car includes a pair of first and second end structures each mounted upon a rail car truck, a pair of side sills extending between the end structures, and a trough structure for carrying coils mounted between the side sills. Each of the side sills has a top chord, a bottom chord and intermediate structure joining the top and bottom chords. The coil car has a greater width measured across the top chords of the side sills tan across the bottom chords of the side sills, and the trough structure is lined with thermally insulative materials.

[0078] In an additional feature of that aspect of the invention, the intermediate structure of each of the side sills includes a web extending between the top and bottom chords, and is inclined at an angle from vertical.

BRIEF DESCRIPTION OF THE DRAWINGS

[0079] For a better understanding of the present invention and to show more clearly how it may be carried into effect, reference will now be made to the exemplary embodiments illustrated in the accompanying drawings, which show the apparatus according to the present invention and in which:

[0080] FIG. 1 a is a top view of one half of a coil car according to the present invention;

[0081] FIG. 1 b if a top view of the coil car of FIG. 1a with decking removed to show the structural skeleton of the coil car;

[0082] FIG. 2 is a side view of half of the coil car of FIG. 1a;

[0083] FIG. 3 a is a cross-sectional view of the coil car of FIG. 1a at mid-span with the one side sill and one set of deck cushions removed;

[0084] FIG. 3 b is a staggered sectional view taken on ‘3b-3b’ of the coil car of FIG. 1a;

[0085] FIG. 4 is a top view of an alternate triple trough coil car to the coil car of FIG. 1a;

[0086] FIG. 5 a is a cross-sectional view of the coil car of FIG. 4 at mid-span, showing a triple trough arrangement having cross bearers with a stepped lower flange;

[0087] FIG. 5 b shows the cross-section of FIG. 5a with coils of various loading configurations shown thereon;

[0088] FIG. 5 c shows a top view of a coil stop of the coil car of FIG. 5b;

[0089] FIG. 6 a shows an alternate mid-span coil car cross-section to that of FIG. 5a having a cross bearer with a horizontal bottom flange,

[0090] FIG. 6 b shows a further alternate mid-span coil car cross-section to that of FIG. 5a, having a cross bearer with an inclined bottom flange;

[0091] FIG. 6 c shows a still further alternate cross-section to that of FIG. 5a;

[0092] FIG. 7 a shows an isometric view of an alternative embodiment of coil car to that of FIG. 1;

[0093] FIG. 7 b shows a mid-span cross-sectional view of the coil car of FIG. 7a;

[0094] FIG. 7 c shows an enlarged cross-sectional detail of a top chord of a side sill of the coil car of FIG. 7a;

[0095] FIG. 7 d shows an isometric detail of the engagement of the coil stop beam with the top chord of the coil car of FIG. 7a;

[0096] FIG. 8 a shows a partial side view of an alternate coil car to the coil car of FIG. 1a;

[0097] FIG. 8 b shows a mid span cross-section of the coil car of FIG. 8a;

[0098] FIG. 8 c shows a staggered cross-section of the coil car of FIG. 8b taken on a section corresponding to staggered section ‘3b-3b’ of the coil car of FIG. 1a;

[0099] FIG. 9 a shows half a cross-section of an insulated trough structure for a rail car similar to that of FIG. 4, taken from a mid-span bolster looking toward an end bulkhead;

[0100] FIG. 9 b shows a cross-section through the end bulkhead taken on “9b-9b” of FIG. 9a;

[0101] FIG. 10 a shows an alternate insulated trough structure half-cross section to that of FIG. 9a; and

[0102] FIG. 10 b shows a detail, from above, of the trough structure of FIG. 10a.

DETAILED DESCRIPTION OF THE INVENTION

[0103] The description that follows, and the embodiments described therein, are provided by way of illustration of an example, or examples of particular embodiments of the principles of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention. In the description that follows, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are not necessarily to scale and in some instances proportions may have been exaggerated in order more clearly to depict certain features of the inventions.

[0104] In terms of general orientation and directional nomenclature, for each of the rail road cars described herein, the longitudinal direction is defined as being coincident with the rolling direction of the car, or car unit, when located on tangent (that is, straight) track. In the case of a car having a center sill, whether a through center sill or stub sill, the longitudinal direction is parallel to the center sill, and parallel to the side sills, if any. Unless otherwise noted, vertical, or upward and downward, are terms that use top of rail TOR as a datum. The term lateral, or laterally outboard, refers to a distance or orientation relative to the longitudinal centerline of the railroad car, or car unit, indicated as CL-Rail Car. The term “longitudinally inboard”, or “longitudinally outboard” is a distance taken relative to a mid-span lateral section of the car, or car unit.

[0105] FIGS. 1 a, 1 b, 2 , 3a and 3b

[0106] By way of general overview, an example of a coil car is indicated in FIGS. 1a, 1b, 2, 3a, and 3b, generally as 20. For the purposes of conceptual explanation of the embodiments illustrated in the various Figures, the major structural elements of coil car 20 (and of the alternate embodiments described herein), are both symmetrical about the longitudinal centerline of the car (as designated by axis CL) and symmetrical about the mid-span transverse section of the car, indicated as TS.

[0107] As shown in FIGS. 1a, 1b and 2, coil car 20 has a longitudinal rolling direction, on straight track, parallel to the longitudinal centerline CL. Coil car 20 includes a pair of end structures 22 and 24. End structures 22 and 24 are mounted on a pair of spaced apart rail car trucks 26 and 28, respectively. Side sills 34 and 36 extend between end structures 22 and 24 and form the main longitudinal structural elements of coil car 20 for resisting vertical loads. An array of cross-members 32 extends outwardly and away from center sill 30 to attach to side sills 34 and 36. A trough structure for carrying coils, generally indicated as 38, is mounted to, and suspended between, side sills 34 and 36.

[0108] As shown in FIG. 3a, trough structure 38 has tree parallel, longitudinally extending cradles or troughs—a central trough 40 lying between two laterally outboard outer troughs 42 and 44. Each trough is shaped to cradle steel coils, or other similar, generally cylindrical coiled loads, between its inwardly and downwardly sloping shoulders, namely sloped plates 46 and 47, 48 and 49, 50 and 51, respectively. More generally, in each of the embodiments described herein each pair of opposed sloped plates define the flanks of a valley, or trough, for cradling coils, and each of the valleys has a flat valley bottom, as described below. Bash valley is centered over a longitudinally extending structural member, whether a center sill or a stringer spaced laterally outboard of the center sill, as described below, with the upper face of the longitudinal structural member also defining the valley bottom. Sloped plates 46 and 47, 48 and 49, 50 and 51 are lined with cushioning in the nature of wood decking 52 that acts as a cushion to buffer coils during loading or travel. This geometry defines longitudinally oriented troughs, that is, troughs in which the winding axis of the coils will be parallel to the longitudinal, or rolling, direction of the rail car. Load stabilising partitions in the nature of end bulkheads 54 and moveable bulkheads, namely coil stops (not shown), discourage longitudinal sliding of coils loaded in troughs 40, 42 and 44.

[0109] Describing now the arrangement of troughs 40, 42 and 44 within trough structure 38, outer troughs 42 and 44 are arranged on either side of central trough 40. Central trough 40 lies directly above center sill 30. When arranged in this fashion, a portion of the upper flange 60 of center sill 30 forms the bottom of the valley of central trough 40. Central trough 40 is carried lower relative to TOR than outer troughs 42 and 44 as indicated in FIG. 3a by dimension 8. Outer troughs 42 and 44 are mounted above stringers 114 and 116 respectively and are carried at the same height as each other relative to TOR. Having outer troughs 42 and 44 carried at a different height than central trough 40, may tend to facilitate placement of the coils in a position to tend to encroach upon or to marginally overlap each other to some extent such that a greater width of coils can be accommodated in a somewhat narrower width of coil car than might otherwise be case.

[0110] Troughs 40, 42 and 44 can accommodate various sizes of coils, as illustrated by the outlines of coils A, B, C, D in FIG. 3b. When coils are not carried in outer trough 42 and 44, central trough 40 can carry a coil having a maximum diameter of 74 inches as indicated by coil ‘A’. The largest diameter of coil that can be accommodated by outer troughs 42 and 44, as illustrated when central trough 40 is not loaded, is 40 inches as indicated by coils ‘B’. Coils C and D illustrate lading conditions for all three troughs at once.

[0111] In greater detail, center sill 30 includes upper flange 60, a pair of parallel vertical webs 62 and 64 and a lower flange 66, all arranged in a rectangular box-shaped form in which the outboard margins of upper flange 60 and lower flange 66 extend past webs 62 and 64, as shown in FIG. 3a. Center sill 30 is of substantially constant cross-section in the medial span between trucks 26 and 28. Internal gussets 68 are welded inside center sill 30 to provide web continuity a each cross bearer location.

[0112] The array of cross-members 32 extends between side sill 34 (or 36, as the case may be) and center sill 30. Array 32 includes bolsters 72 and cross bearers 74. Bolsters 72 are located amidst end structures 22 and 24, above railcar trucks 26 and 28. Cross bearers 74 are spaced apart one from another at successive longitudinal stations along center sill 30 between end structures 22 and 24. As shown in FIG. 3a, each of cross bearers 74 has a web 76, an upper flange 78 and a lower flange 80. Upper flange 78 is carried at the level of upper flange 60 of main center sill 30, and is welded at its proximal, or inboard, edge thereto. Similarly, lower flange 80 is carried horizontally at the level of, and has its inboard edge welded to, lower flange 66. Web 76 extends from web 64 of center sill 30 beyond the outboard, or distal, ends of upper and lower flanges 78 and 80 to form a substantial tongue, or tab 82 suitable for welding in a lap joint to web stiffeners of the structure of side sills 34 and 36, as shown in FIG. 3a.

[0113] In terms of major structural elements (that is, excluding handrails, brake line fittings, and ancillary items), coil car 20 is symmetrical about center sill 30, such that the structure of side sills 34 and 36 is the same. Consequently, a description of one will also serve to describe the other. Referring to FIG. 3a, side sill 36 has an upper flange assembly 86, a lower flange assembly 88, and an intermediate structure 90 in the nature of a web, or webbing 92.

[0114] Examining each of these in turn, upper flange assembly 86 has a top chord member 94 in the nature of a hollow rectangular steel tube 96, upon which pin locating plate 98 is mounted. Plate 98 has an inwardly extending perforated strip or tongue 100, the perforations having a constant pitch, and being of a size and shape suitable for engagement by the locating pins of moveable bulkheads or cross-beams, namely the coil stops (not shown), used for providing longitudinal restraint of the coiled materials once loaded. Also located intermittently along a more laterally outboard region of plate 98 are eyes 102 for locating a cowling or cover (not shown) to protect coils loaded on coil car 20 from exposure to rain or snow. Lower flange assembly 88 includes a bottom chord member 104 in the nature of a hollow rectangular steel tube 106.

[0115] Webbing 92 extends between, and connects upper flange assembly 86 and lower flange assembly 88. Webbing 92 includes an upwardly and outwardly inclined steel web in the nature of a side panel sheet 108. Sheet 108 is reinforced at the longitudinal station of each successive cross bearer by a web stiffener, or brace, in the nature of a section of channel 110. Channel 110 extends between tubes 96 and 106 along the inner face of sheet 108. Channel 110 is a C-channel having its back facing inward and its toes welded to sheet 108. Channel 110 provides an attachment site for tab 82 of cross bearer 74 to allow mounting of cross bearers 74 to side sills 34 and 36. Specifically, the sides, or legs, of channel 110, each lie in a vertical plane perpendicular to the longitudinal centerline of car 20. As such one side of channel 110 is aligned with the web of each successive cross bearer 74 and thereby provides a lap surface to which respective tabs 82 of each cross bearer 74 are welded in a lap joint. Sheet 108 has an upper strip, or margin, that is bent to provide an overlapping band welded at a lap joint to the outer face of rectangular steel tube 96. Similarly, the lower margin, or band, of sheet 108 overlaps, and is welded in a lap joint to, the outer face of the bottom chord member, namely tube 106.

[0116] A gusset 112 provides vertical web continuity at the longitudinal station of the web of each cross bearer 74 to that portion of channel 110 extending to a height lower than horizontal lower flange 80. Gusset 112 extends downward to meet the uppermost side of the bottom chord member, namely tube 106, gusset 112 being smoothly radiused on its most inboard edge to tend to reduce the stress concentration that might otherwise develop at the juncture between cross bearer 74 and side sill 34, or 36 as may be.

[0117] Longitudinal structural elements, in the nature of stringers 114 and 116, noted above, are mounted upon cross bearers 74 at a medial location along upper flange 78 somewhat more than half way from the car centerline CL to the distal, or outboard, extremity of cross bearer 74. Each stringer 114 and 116 spans the length of coil car 20 and is mounted to cross bearers 74 intermediate center sill 30 and each side sill 34 and 36. Stringers 114 and 116 are secured by welding to trough structure 38 and top flange 78 of cross bearers 74. Stringers 114 and 116 function to bridge the gap, or space, between adjacent cross bearers and so to tie cross bearers 74 together in their midst, (i.e., at a transversely mid-span location lying between center sill 30 and side sill 34 or 36 as the case may be), and also provide the backbone of side troughs 42 and 44. Each of stringers 114 and 116 has a hollow, closed section made by employing an upwardly opening channel 118 and welding a cover or closure plate 119 across its toes. Sloped outboard and inboard side plates 46 and 47 (or 51 and 50), respectively, extend on an upward slope away from closure plate 119, the junctures of plates 46 and 47 (or 51 and 50) with closure plate 119 occurring above the respective toes of channel 118. At its outboard edge, sloped side plates 46 and 51 are each welded in a lap joint to the inboard face of tube 96 of top chord assembly 94.

[0118] Vertical web continuity is provided by a web plate, or outboard web 124 located in the same plane as web 76 of cross bearer 74. Gusset 124 has a lower edge welded to upper flange 78 of cross bearer 74, and extends upwardly therefrom to connect to a sloped flange 125 that lies against the underside of sloped side plate 46. An inboard toe of gusset 124 abuts the outboard upwardly extending leg of channel 114, (or 116) and an outboard edge of gusset 124 is welded in a lap joint to one of the legs of channel 110 of intermediate structure 90. Web stiffeners 126 are welded to both the fore and aft faces of gusset 124. Web stiffeners 126 extend between sloped flange 125 and flange 78, perpendicular to sloped side plate 125, from a location under the mid-point of cushioning decking 52, to discourage buckling of gusset 124.

[0119] An inboard web 128 is also located at the longitudinal station of the plane of the web of cross member 74 and has a first, lower, edge abutting flange 78, an outboard toe abutting the inboard upturned leg of channel 118, a first upper inclined edge abutting slope flange 127 directly below shoulder plate 50 (or 47) of outer trough 44 (or 42), and a second upper inclined edge abutting sloped flange 129 directly below shoulder plate 49 (or 48) of trough 40. Flanges 127 and 129 can be fabricated from a single piece of flat bar bent to form the vertex between trough 40 and tough 42 (or 44). Web stiffeners 130 are provided to extend from inclined flange 125 to flange 78, web stiffeners 130 running perpendicular to shoulder plate 49 (or 48) from a point the midst of decking 52. Further web stiffener 132 run perpendicularly from flange 78 to the vertex formed at the intersection of shoulder plates 49 and 50. Further gussets 134, 136, and 138 are located between, and run vertically perpendicular to flanges 78 and 80 at locations directly beneath web stiffeners 132 and the toes of channel 120.

[0120] Side sills 34 and 36 have an inclined orientation with respect to the vertical, as noted above. That is, webbing 92 is inclined at an angle η from the vertical such that the width W1 measured across respective top chords 88 of side sills 34 and 36 is greater than the width W2 measured across respective bottom chord members 104 of side sill 34 and 36. (For the purposes of illustration (W1/2) and (W2/2) have been shown as measured from the centreline CL). Bottom chord members 104 are located at a height relative to TOR that is lower than the lower flange 66 of center sill 30. It is advantageous for the top chords of the side sills to be widely spread to tend to increase the trough width, and hence the maximum coil diameters that can be carried within the AAR plate B width limit. At the same time, increasing the depth of section to increase the second moment of area, and hence resistance to flexure under vertical loading, may tend to encourage use of bottom chords that are stepped laterally inward relative to the top chords, as shown, to fall within the inwardly sloping underframe limit such as is permitted under AAR plate “B” or plate “C” envelope shown in dashed lines and indicated as “UF”.

[0121] Although different angles could be used for the slopes of the sides of central trough 40 and side troughs 42 and 44, in the embodiment illustrated in FIG. 3a they are the same. Their angle, (that is, the angle of sloped sheets 46, 47, 48, 49, 50 and 51) when measured from the horizontal, is greater than 20 degrees, and in general lies in the range of 23 to 29 degrees. It is preferable that the angle be greater than 24.22 degrees, (at which L/V=0.45) and less than 28 degrees, and it is most preferred that the angle be 27 degrees or thereabout.

[0122] Side sills 34 and 36 have a maximum depth of section at mid-span 70 to provide resistance against the bending moment induced by the loads carried by coil car 20. Considering the side view of FIG. 2, moving away from the mid-span 710, the portion of side sill 34 having the greatest depth of section ends at a point designated as “X” in FIG. 2. At point “X” bottom chord member 104 is obliquely truncated and welded to a doglegged upswept fender, or flange 140. Upswept flange 140 follows the lower edge of sheet 108 as it narrows in a transition portion 142 from the deep, mid-span or medial portion 144 to the narrow, or shallow, end structure portion 146, the upswept flange 140 reaching a sufficient height to clear trucks 26 and 28, as the case may be.

[0123] FIGS. 4, 5 a and 5b

[0124] Referring to FIGS. 4, 5a and 5b, in another embodiment a coil car is generally indicated as 200. Coil car 200 is generally similar to coil car 20. It has a center sill 202, a pair of side sills 204 and 206 and cross bearers 208 for tying side sills 204 and 206 to center sill 202. The arrangement of center sill 202, cross bearers 208 and side sills 204 and 206 support a trough structure 210. Trough structure 210 has three parallel, longitudinally extending troughs 212, 214 and 216. Each trough is shaped to cradle steel coils, or other similar loads, between its inwardly and downwardly sloping opposed flanks, or shoulders plates 218 and 220, 222 and 224, 226 and 228, respectively. Troughs 212, 214 and 216 terminate at either end of car 200 by transverse wall members in the nature of end bulkheads 215, 217.

[0125] Center sill 202 is similar to center sill 30 of coil car 20. It includes an upper flange 230, a pair of parallel vertical webs 232 and 234 and a lower flange 236, all arranged in a rectangular box-shaped form in which the outboard margins of upper flange 230 and lower flange 236 extend past webs 232 and 234.

[0126] Each cross bearer 208 has an upper flange 240, a lower flange 242 and a web 244. Unlike upper flange 78 of coil car 20, upper flange 240 is carried above the level of upper flange 230 of center sill 202, and lies against the underside of trough structure 210. As upper flange 240 extends from side sill 204 and 206, it slopes downwardly and upwardly, as the case may be, to match the orientation of shoulder plates 218, 220, 222, 224, 226 and 228, Web 244 extends between lower flange 242 and trough structure 210. At its outboard end or tip, web 244 is welded to the structure of side sills 204 and 206 in a lap joint. As above, the upper flanges of the center sill and longitudinal stringers form the bottom of the valley of the respective troughs.

[0127] Lower flange 242 is a stepped lower flange carried at a level higher than the lower flange 236 of center sill 202. At its inboard edge, lower flange 242, has an inboard portion 247 welded to lower flange 236. Inboard portion 247 extends on an upward slope outboard and away tom lower flange 236 to join a horizontal transition portion 248. In turn, transition portion 248 joins an upwardly sloped portion 249 that extends toward side sill 206 or 208, as the case may be. The sloped portion 249 of lower flange 236 has been trimmed short of side sill 204 or 206. The upward slope of inboard portion 247 provides a larger space, indicated generally as ‘B’ in which to locate a brake line. This is advantageous, since it is not then necessary to punch a hole through web 244 for the brake line, saving fabrication and installation costs, and avoiding a stress concentration in web 244.

[0128] Each side sill 204, 206 has an upper flange assembly 250, a lower flange assembly 252, and an intermediate structure 254 in the nature of webbing 256. Upper flange assembly 250 has a top chord member 258 in the nature of a hollow generally rectangular steel tube 260. Steel tube 260 is a formed section having a lower portion on a dog leg bend do match the angle of inclination ρ of webbing 256. Unlike top chord 94 of coil car 20, top chord 258 is not provided with an inwardly extending plate such as plate 98 for locating the pins of the moveable bulkheads (not shown), thus tending to permit trough structure 210 to accommodate coils of a larger diameter within the limits of AAR plate B than would otherwise be the case. Rather a perforated formed channel, or strip, 259 is mounted along the face of the inner web of top chord 258, the perforations serving as sockets for receiving, and retaining, the lugs of a coil stop 280 described below. An angle iron 261 is welded along the inboard face of the inboard web of top chord member 258, to bear the weight of the coil stop. That is, the coil stop can slide along angle iron 261 and be locked in place by seating removable pins in strip 259 as described below. The arrangement of lower flange assembly 252 and webbing 256 is generally similar to that described earlier in respect of lower flange assembly 88 and webbing 92 of coil car 20.

[0129] Longitudinal structural elements in the nature of stringers 262 and 264 are mounted upon cross bearers 208 at a medial location along web 244 somewhat more than halfway from the car centerline CL to the distal, or outboard, extremity of cross bearer 208. Stringers 262 and 264 seat in pockets or recesses 263 and 265 formed in web 244. Stringers 262 and 264 function to tie cross bearers 208 together in their midst, i.e., at a mid-span location, and also provide the backbone of side troughs 214 and 216. Each stringer 262, 264 has a hollow, rectangular steel section in the nature of a tube 266. Respective sloped side plates 224 or 226 and 222 or 228 each have a lip welded to the respective inboard and outboard uppermost corners of tube 266 and extend on an upward slope away therefrom. At its outboard edge, sloped side plate 222 (or 228) has a bent lip welded in a lap joint to the inboard face of tube 260 of top chord assembly 258. The undersides of sloped side plates 224 (or 226) and 222 (or 228) are welded to the undulating upper flange 240 of cross bearer 208.

[0130] Tread plates, generally indicated as 272, are mounted to the top surface of tube 266 intermediate attachment sites 274 where wood decking 52 is fastened to trough structure 210, as best shown in FIG. 10. The arrangement of tread plates 272 in this way does not interfere with wood decking 52 mounted within outer troughs 214 and 216. Similarly, tread plates 272 are generally sufficiently thin so that when coils are loaded in outer troughs 214 and 216, the coils do not touch tread plates 272 thereby tending to avoid damage by tread plates 272. Tread plates 272 provide a no-skid roughened surface to the walkways defined in the valley bottoms and tend to permit railway personnel to secure a coil during loading of coil car 200. The walkways so defined are fixed in position relative to the trough structure, and do not require special mechanisms for deployment or retraction.

[0131] Web stiffeners 276 run perpendicular to lower flange 242 to intersect the vertex formed at the intersection of shoulder plates 224 and 226. Further gussets 268 and 270 are located between, and run vertically perpendicular to lower flange 242 and the lowermost corners of tube 266.

[0132] The arrangement of troughs 212, 214 and 216 is generally similar to that of troughs 40, 42 and 44 of coil car 20. Outer troughs 214 and 216 are arranged on either side of central trough 212. Central trough 212 lies directly above center sill 202 and is carried lower relative to TOR than outer troughs 214 and 216. Each outer trough 214 and 216 is mounted above stringers 262 and 264 and carried at the same height relative to TOR as the other.

[0133] Troughs 212, 214 and 216 can accommodate various sizes of coils, as illustrated by the outlines of coils shown in FIG. 5b. When coils are not carried in outer troughs 214 and 216, central trough 212 can carry a coil having a maximum diameter of 84 inches. The largest diameter of coil that can be accommodated by outer troughs 214 and 216 when central trough 212 is not loaded, is 48 inches.

[0134] As noted above in the context of coil car 20 of FIGS. 1a, 1b, 2, 3a and 3b, troughs 212, 214 and 216 of FIGS. 4, 5a and 5b have slope angles, indicated in FIG. 5b as θ1, θ2 and θ3. In general, these angles need not be the same, although it is convenient, and preferred, that a single angle be chosen. The range of angles chosen for any of θ1, θ2 and θ3 is greater than 20 degrees. As above, the angles can be chosen in the range of 23 to 29 degrees, preferably being 24.2 or more, and 28 degrees or less, and most preferably being about 27 degrees.

[0135] In the embodiment illustrated in FIGS. 5a and 5b, in single coil mode, central trough 212 can cradle a coil up to 84 inches in diameter, as indicated in dashed lines as C84. A 74 inch coil is indicated as C74. Similarly, in a two-coil loading configuration, each of the outboard troughs 214 or 216 can accommodate a coil of up to 48 inches, indicated as C48. In the triple coil configuration each of the troughs hold a 30 inch coil, indicated as C30. Alternatively a 38 inch diameter coil, indicated as C38, can be accommodated in central tough 214 while two 30 inch coils are cradled in outer troughs 212 and 216.

[0136] A transversely extending member, or cross beam member, is indicated as 275, and spans the trough structure from side sill 206 to side sill 204. As illustrated in FIG. 5b, member 275 is in a position to restrain longitudinal motion of coils mounted in any of the three troughs. As indicated by angle ψ, when measured at mid-height (in this case, at the level of its horizontal web) cross beam member 275 subtends a portion of a minor arc of coil C74. In the preferred embodiment ψ is greater than 108 degrees, typically being about 122 degrees for coil C74 and about 112 degrees for coil C84.

[0137] The movable cross-beam member 275, namely coil stop 280, is shown in FIGS. 5b and 5c. It has the general form of an I-beam set on its side such that flanges 282, 284 of the I-beam stand in vertical planes perpendicular to the longitudinal centerline of car 200, and web 283 lies in a horizontal plane between the flanges. Web 283 is perforated, having a number of apertures in the nature of round holes 285 formed in it to reduce its weight. An end plate 286 is welded across each end of the I-beam, each end plate having through holes for accommodating locating releasable retainers in the nature of pins 288. Each pair of locating pins is joined by a lanyard 290. Lanyard 290 is preferably a cable but could also be a wire, cable, chain or strap. In use, pins 288 extend through plate 286 to seat in a pair of apertures, or sockets, in strip 259, thus preventing coil stop 280 from shifting in the fore-and-aft (i.e., longitudinal) direction relative to the troughs. When so engaged, a locking member 292 pivots on a pin to bear against a shoulder of pins 288, thus preventing them from disengaging from strip 259. In use, locking member 292 is held in place by a laterally inward retainer 294 that prevents the handle of locking member 292 from moving laterally inboard. To release pins 288, the handle of locking member 292 is pivoted upwards, such that locking member 292 no longer blocks the retraction of the shoulders of pins 288. Pulling on lanyard 290 then releases pins 292, permitting coil stop 280 to be moved to a different location. A slider 296 is mounted under each of end plates 286 and bears upon angle iron 261. It is advantageous for slider 296 to have a sliding bearing surface, such as a nylon or high molecular weight polymer pad or facing.

[0138] FIGS. 6 a, 6 b and 6c

[0139] FIG. 6 a shows an alternative embodiment of coil car to that of FIG. 4, 5a and 5b, indicated generally as 300. Coil car 300 differs from coil car 200 in that, rather than having upwardly stepped cross bearers such as cross bearers 208, coil car 300 has cross bearers 302 having a horizontal lower flange 304 carried flush with the bottom flange of center sill 306. Cross bearer 302 has a correspondingly deeper web 308, and gussets 310, 312 and 314. A further radiused gusset 318 lies in the plane of web 308 and extends between lower flange 304 and bottom chord 316. Coil car 300 has trough structure 210 as described above and employs coil stop 280, and related fittings, also as described above.

[0140] FIG. 6 b shows another alternative embodiment of coil car to that of FIGS. 4, 5a and 5b, indicated generally as 320. Coil car 320 differs from coil car 200 in having cross bearers 322 having a lower flange 325 that extends in an inclined plane upward and outward from center sill 324. Corresponding changes are made in the size of web 326 of cross bearer 322, and in gussets 328, 330, 332 and 334.

[0141] In the alternative embodiment shown in FIG. 6c, a coil car 340 can be constructed without center sill between rail car trucks 26 and 28. That is, stub sills can be employed at either end of the coil car body with no main sill between deep side sills 342 and 344. Coil car 340 has transverse structural members in the nature of cross bearers 346 that extend as continuous beams between a pair of deep side sills 348 and 350. Gussets 352 and 354 are built up in the manner of gussets 124 and 128 noted above, to support upper flanges 356, 357 and 358, that are similar to items 125, 127 and 129, noted above. The general stringer, trough sheet a cushion structure is also similar to that of car 20. The upper flange 360 of cross bearer 346 is supported at the juncture with flanges 358 by gussets 362. Cross bearer 346 has a continuous bottom flange 364.

[0142] FIGS. 7 a, 7 b, 7 c and 7d

[0143] FIG. 7 a is an isometric view of a preferred embodiment of coil car, indicated generally as 400. It has first and second end sections 402, 404, carried over spaced apart rail car trucks 406, 408. Side sills 410, 412 extend between end sections 402 and 404. A modest center sill 414 extends from end to end of coil car 400 along the longitudinal centerline, and terminates at draft pockets with draft gear and couplers in the manner of rail road cars generally. Main bolsters extend laterally outboard from center sill 414 at the truck centers to meet side sills 410 and 412. An array of cross bearers 418 is spaced along car 400, and is slung between side sills 410 and 412, and center sill 414 generally as described above in the context of car 200.

[0144] A trough structure, generally indicated as 420, is mounted above, and supported by, cross bearers 418 and between side sills 410 and 412. That is, side sills 410 and 412 extend longitudinally along the outboard edges of, and define bounds of, trough structure 420. As in the other embodiments, side sills 410 and 412 lie at, or just within, that is, within two inches of, the AAR Plate B width limits. Trough structure 420 includes a central trough 422, and left and right hand laterally outboard troughs 424 and 426, having the same structure and geometry as troughs 212, 214 and 216 of coil car 200, described above. Each of troughs 422, 424, and 426 has a walkway 421, 423, 425 with tread plates 428 located at the base, or groin, that is, the valley bottom, of the particular trough. Movable coil stops, each indicated as 430, are mounted between side sills 410 and 412 as more fully described below. Each coil stop has a stile, or step, 431 with a roughened tread plate 432 and hand grabs 433 to aid personnel in walking along the valley of central trough 422. Although six coil stops are illustrated, this is representative of any reasonable number of coil stops more generally, such as may be appropriate for anticipated loading conditions, and overall maximum car weight when loaded. Coil car 400 has a removable cover, indicated generally in FIG. 7b as 405, and cover guides 407 mounted at the corners of the car on the end bulkheads to aid in locating cover 405 in place.

[0145] Coil car 400 differs from coil car 200 in a number of respects. First as shown in FIG. 7b, lower flange 434 of cross bearer 418 has an upwardly angled portion 435 adjoining the lower flange 436 of center sill 414, and a flat portion 437 extending from portion 435 to a distal tip next to the lap joint of web 438 with the vertical stiffener 440 of side sill 410 (or 412, as may be).

[0146] Second, the construction of coil stop 430, and its mating engagement strip of side sill 410 (or 412) differs from that of coil stop 280 and strip 259 described above. As with coil stop 280, coil stop 430 has the construction of an I-beam 442 having flanges 443 and 444 lying in spaced apart vertical planes, and a web 445 lying in a horizontal plane between flanges 443 and 444. As above, web 445 is perforated, having lightening holes indicated as 446. I-beam 442 is capped at either end by end plates 448. However, rather than the horizontal pin arrangement of coil stop 280, end plates 448 have toes 450 that extend past flanges 443 and 444 in the longitudinal direction of car 400. Toes 450 each have rollers 452 mounted to them to engage a load bearing member of the side sill, as described below. In addition, a pair of perforated bars, or straps 451 and 452 are welded to the laterally outboard faces of plates 448. Strips 451 and 452 stand in parallel horizontal planes and extend outwardly from end plates 448. The perforations 454 and 455 in strips 451 and 452 are aligned with each other. Perforations 454 and 455 are slots having an oblong shape to permit lateral tolerance in the placement of coil stop 430 relative to side sills 410 and 412.

[0147] Third, the construction of the top chord is different from that of top chord 250. As above, each of side sills 410 and 412 has the same profile, given that, in terms of primary structure, coil car 400 is structurally symmetrical both about the longitudinal centerline and the transverse central plane of the car. Each of side sills 410 and 412 has a top chord assembly, generally indicated as 456, a bottom chord indicated as 457, and a webbing assembly 458 extending between the top and bottom chords. Webbing assembly 458 includes both a web sheet 460 and stiffeners in the nature of posts 462 that extend between the top and bottom chords at longitudinal stations corresponding to the longitudinal planes of the webs of cross bearers 418, to which they are welded.

[0148] In contrast to the dog-legged closed box section of top chord 258, top chord assembly 456 includes a trapezoidal hollow tube 464 having inner and outer walls parallel to the slope angle of web sheet 460, and a perpendicular base wall. The top wall 465 of hollow tube 464 is formed to lie in a horizontal plane. An inwardly opening C-shaped firmed channel member 466 has a back 467 and parallel legs 468 and 469. Leg 468 lies upon, and is welded to, top wall 465, such that back 467 stands in a vertical plane. A cowling support bracket 470, is welded to back 467. Cowling support bracket 470 has the form of an angle having a relatively tall vertical leg 471 whose toe is welded to the outboard face of back 467 of channel member 466, and a relatively short inwardly extending horizontal leg 472 that extends from the upper end of leg 471 inboard toward the car centerline. Leg 472 is a flange having sufficient width (i.e., the length of the leg from the angle to the tip of the toe) to support coil cover 405 such as commonly used on coil oars to protect the lading from rain and snow. (More generally, covers such as cover 405 can be used with each of the other embodiments described herein). The upwardly facing surface of leg 472 and the corresponding upwardly facing surfaces of end bulkheads 484 define respective longitudinal and transverse edges of a rectangular periphery bounding the trough structure. The interface surface of the boundary matches the footprint of cover 405, such that the trough structure, walkways and coil stops are carried within the footprint (i.e., within the vertical projection of area) of cover 405 when installed. Cover 405 is removable to permit loading of coils into the trough structure.

[0149] As best seen in the enlarged detail of FIG. 7c, the upper face of leg 468 provides a trackway, or bearing surface, upon which rollers 452 can travel when coil stop 430 is not locked in place. Strips 451 and 452 are carried on plates 448 at height to bracket upper leg 469 of formed channel member 468 in a sandwich arrangement. Upper leg 469 has perforations 471 such that a securement or locking member, such as pin 474, can be inserted through strip 451, leg 469 and strip 452. Pin 474 has a head 475 of sufficient size to seat on the upper face of strip 451, and a link 476 to which a cable, chain, or similar retraction means such as lanyard 290can be attached. When pin 474 is installed, it is in a double shear condition. Two pins 474 are used at each end of coil stop 430 at any given time.

[0150] The pitch of the oval, or oblong, holes, apertures, slots or namely perforations 454 in strips 451 and 452 is slightly different from the pitch of perforations 471 in leg 469 such that a movement of less than a full pitch will cause a different set of holes to align, allowing a finer choice of positions. That is, the pitch of holes in leg 469 is 3 inches. The pitch of the slots in strips 451 and 452 is 1.8 inches. Given the 8 slot arrangement, the different pitches are such that at least 2 sets of slots and holes will line up at every 0.6 inch increment in travel along the leg 467. In this way, perforations 454 in strips 451 and 452, and perforations 471 in strip 469 act as co-operating indexing members. The pitch of one set of indexing members is different from the pitch of the other, such that the effective resolution, or incremented graduation, is less either pitch by itself.

[0151] The mounting of rollers 452 on the extending lugs or toes 450, or lugs, of end plates 446 gives a relatively long wheelbase for coil stop 430 and facilitates operation of coil stop 430. While rollers are preferred, in an alternative embodiment a polymeric slider pad could be used in place of rollers as used in coil car 200. Nylon pads, or cushions, 477 are mounted to the outside faces of flanges 443 and 444 in a position to contact coils carried in the troughs, and tend to discourage damage to the edge of the coils. Similar pads 478 are mounted to the inward face of the end bulkheads 484.

[0152] In operation, rail yard personnel can ascend the end walkways 480 of car 400 by means of the ladders 482 located at the corners of the car. Personnel can step over end bulkhead 484 and walk along the walkways provided along any of troughs 422, 424, or 426. A step with a tread plate 486 is provided on end bulkhead 484 opposite the end of the walkway of central trough 422. In stepping over each coil stop 430 personnel can steady themselves with the assistance of the safety appliances, namely handles 433 having the form of U-shaped, downwardly opening hand rungs 488.

[0153] In the process of loading a coil, the coil stop pins are disengaged from leg 469 and coils stops 430 are urged to positions leaving a long enough space for the coil (or coils, if more than one of the troughs is being used) to be loaded. Each coil is lowered into place, typically by a crane. The next adjacent coil stops 430 are urged into position snug against the coil (or coils), or as nearly so as practicable, and the locking members, namely pins 474 are engaged as shown in FIG. 7b. Shimming or packing materials are used if required. The movement of coil stop 430 can be either by a single person working in the center trough, or by two persons co-operating to push on either side from the outer troughs. The next coil, or coils are placed in position, and further coil stops are moved into position, and so on.

[0154] FIGS 8a, 8b and 8c

[0155] In a further alternative embodiment, a coil car 480 can be constructed with a center sill having a variable depth of section. As above, coil car 480 is symmetrical about both it longitudinal centerline and a transverse axis at mid-span between trucks 26, 28, hence only half illustration is provided to represent both ends. Referring to FIGS. 8a, 8b, and 8c, the structure of coil car 480 includes a center sill 482 extending longitudinally between rail car ends 484 and 486. Center sill 482 is the primary longitudinal structural element in coil car 480 for resisting vertical loads. Longitudinally extending side sills 490 and 492 are tied to centre sill 482 by an array of cross-members 419 that extend outwardly and away therefrom. The arrangement of center sill 482, cross bearers 448 and side sills 490 and 492 support trough structure 494. Trough structure 494 has three parallel, longitudinally extending troughs 496, 497 and 498. Central trough 498 is arranged between outboard troughs 496 and 497 and is carried at a lower height relative to TOR than outboard troughs 496 and 497.

[0156] Examining center sill 482 in greater detail, it has a deep central portion 500 located intermediate two relatively shallow end portions 502 and 504. Central portion 500 has a constant depth of section. The transition from the relatively shallow section at end portions 502 and 504 to the deep section at central section 500, occurs as a step, as shown in FIG. 8a. A center sill of variable section, having shallow ends to clear the trucks, and deeper mid-span depth, whether constant or tapered, are often referred to as fish belly center sills. Alternatively, in another embodiment, central portion 500 can have a variable depth of section, the depth of section being greatest at a mid-span 70 distance between end portions 502 and 504. The maximum depth of section is provided at mid-span 70 to correspond to the location of the greatest bending moment. The transition from the relatively shallow section at end portions 502 and 504 to the deep section at central section 500, occurs in a substantially linear fashion, that is, the section tapers linearly moving away from the mid-span 70.

[0157] Center sill 482 is cambered such that, in an unloaded condition, the mid-span clearance above top of rail is greater than at the truck centers. The camber allows the center sill 482, in an unloaded condition, to have a clearance above top of rail (TOR) at mid-span 70 that is greater than the clearance above TOR at a location away from mid-span 70. In this way the depth of section of centre sill 482 at mid-span 70 can be maximized, while maintaining the minimum required clearance above (TOR) for the coil car when in a loaded condition.

[0158] Referring to FIG. 8b, fish belly center sill 482 includes an upper flange 510, a lower flange 512, and a pair of parallel vertical webs 514 and 516 that extend therebetween. Upper flange 510 of fish belly center sill 482 lies flush with the upper flange 506 of cross bearers 489. Vertical webs 514 and 516 extend below lower flange 508 of cross bearers 489 to join lower flange 512. At the location where lower flange 508 of cross bearers 489 intersect with vertical webs 514 and 516, a gusset 518 is provided between vertical webs 514 and 516. A plate 520 is welded to lower flange 502 of fish belly center sill 482 to provide additional enforcement.

[0159] In this embodiment, a different side sill configuration is used. As shown in FIG. 8b, each of side sills 490 and 492 includes a top flange assembly 526 and a web 528. No bottom flange assembly or bottom chord member is provided. The structure of side sills 490 and 492 does not extend below lower flange 512 of fish belly center sill 482, But rather terminates at the level of the lower flange of cross bearer 489. Top flange assembly 526 has a top chord member 530 in the nature of a hollow rectangular steel tube 532. Web 528 has a bent upper margin welded to the outer face of rectangular steel tube 532. Web 528 extends downwardly, and inwardly on an angle, and is attached to the ends of cross bearers 489.

[0160] The trough structure of coil car 480 is the same as trough structure 38 of coil car 20, described above. A fish belly center sill coil car can also be manufactured having the main sill and cross bearer construction of coil car 480, and the trough structure of either coil car 200 or coil car 400, as shown in the Figures and described above, including internal walkways in the central or side troughs, or both. It will be understood that a center sill coil car, as shown in FIGS. 8a, 8b and 8c, can have coil stops such as coil stop 180 or 230, and coil stop retention means as described above.

[0161] FIGS. 9 a, 9 b, 10 a and 10b

[0162] FIGS. 9 a and 9b show portions of a rail road coil car 550 whose structural elements are as described above in the context of rail car 200, and where those elements are common, the same identification numerals are employed. Coil car 550 differs from car 200 (and car 400) by having an insulated trough structure. FIG. 9a shows a half-section of coil car 550 taken from in front of the last full depth cross bearer toward end bulkhead 215 (or 217). As above, since car 550 is symmetrical, a description of one half is sufficient to describe both halves. Coil car 550 has a central trough 553 having left and right hand opposed inclined slope sheets 554 and a pair of left and right hand outboard troughs 555 each having opposed inboard and outboard inclined slope sheets 556, 558 bearing the same proportionate lengths as the corresponding slope sheets of car 200. Sheets 554, 556 and 558 are steel plates that overlie an array of cross bearers such as cross bearers 208. Troughs 553 and 555 are lined with coil cushioning members in the nature of wooden planking 560, generally similar to wood decking 52 noted above, held in place with respective retaining brackets 561, 562, and 563.

[0163] Respective layers of load supporting insulating material arm indicated as 564, 565, and 566. It is advantageous that this material be a ceramic or ceramic-like material having relatively low thermal conductivity as compared to steel, and a relatively high crush strength suitable for supporting the relatively concentrated load exerted under tangent contact of large steel coils. This material is a calcium silicate panel material identified as Marinite I, (t.m.) supplied by BNZ Materials, Inc., of 400 High Street, Iron Hose Park, North Billerica, Mass. 01862. Insulating layers 564, 565, and 566 are roughly ¾ inches thick. According to BNZ product literature, calcium silicate panels of this nature do not support combustion and can be used in contact with objects in excess of 1000 F.

[0164] Insulating layer 564, 565, and 566 are overlain by load spreading protective layers, or liners, in the nature of respective wear plates 568, 569, and 570, made of a bent steel plate of ½ inch thickness. Insulating layers 564, 565, and 566 are nailed to planking 560. Wear plates 568, 569, and 570 are also maintained in place by retaining brackets 561, 562, and 563. Each of wear plates 568, 569, and 570 present an engagement, or bearing surface 572, 573, or 574 respectively, to coils positioned in troughs 553 and 555, the size of the respective bearing surfaces measured along the slope being sufficient to accommodate the range of coil sizes for which the car is designed.

[0165] In addition to the deck insulation thus described, car 550 has insulation mounted to end bulkhead, 215 (or 217). In the section of FIG. 9b, the top chord of the side sill is indicate as 250, as above. An upper cross-member 574 in the form of an I-beam turned on its side extends across car 550 from top chord to top chord. The endmost inclined cross member is a channel indicated as 575. Channel 575 is mounted on its side, with toes inward against a trough endwall panel member in the nature of a bulkhead sheet 576. Channel 575 runs on the same stepped slope profile as cross bearers 208 from center sill 202 to side sill top chord 250, the outboard tip being mitred to locate against vertical web 254 and underneath top chord 250 in a manner similar to cross bearer member 208 shown in FIG. 9a.

[0166] Bulkhead sheet 576 extends across the width of coil car 550 from web 256 of one side sill, to web 256 of the other side sill, and is trimmed to accommodate top chord 258. Bulkhead sheet 576 has an upwardly extending lip 580 that stands proud of (that is, higher than) the top flange of top chord 258, lapping against the longitudinally inboard facing surface of the inboard flange of upper cross member 574.

[0167] A layer of insulating material for insulating the end bulkhead wall, (namely bulkhead sheet 576,) in the nature of a ceramic or ceramic-like material is indicated as 582. It is preferred that insulating material 582 be a calcium silicate structural insulation, such as Marinite I (t.m.) noted above, and that the lower edge (as installed) of the insulating layer be formed, or trimmed, to match the sloped profile of slope sheets 554, 556, 558 and the top flange of center sill 202. The upper edge of insulating material 582 conforms to the upper edge of end bulkhead sheet 576. In contrast to the bulkhead sheets of car 400, of FIG. 7a, bulkhead sheet 576 does not have cushioning material like cushioning material 478 in the nature of a high molecular weight polymer that might be prone to melting or catching fire. Rather, insulating material 582 is captured between bulkhead sheet 576 and an end bulkhead liner, or wear plate, 584, that has a bent lip, or leg 586 mating with the uppermost tip of the innermost flange of cross member 574. Wear plate 584 has a major portion, being a depending sheet terminating at, abutting and attached to, slope sheets 554, 556 and 558. Wear plate 584 may tend to protect insulating layer 582 from accidental damage due to coil mishandling, and presents a smooth, hard surface free of flammable or meltable materials toward coils carried in troughs 553 or 555.

[0168] In the embodiment of FIG. 10a, a rail road coil car 600 has the same construction as rail road car 550, except insofar as wooden cushioning planking is not employed. Rather, insulating layers of structural thermal insulation, indicated as 602, 603 and 604, respectively, are mounted directly on slope sheets 606, 607 and 608. A stop strip 609 is welded to the upper flange of the center sill to provide an abutment against the lower edge of thermal insulation 602, thus to discourage thermal insulation 602 from migrating down the slope of sheet 606 toward center sill 202. Insulating layers 602, 603, and 604 are overlain by load spreading protective layers, or liners, in the nature of respective wear plates 610, and 611, and 612, each made of a bent steel plate of ½ inch thickness. Wear plate 610 has minor bent legs formed as tabs 612 folded over the vertex between slope sheets 606 and 607. Tabs 612 are bolted to slope sheet 607 in reliefs formed in insulating layer 603 and wear plate 611. The head of the bolt 614 lies shy of the plane of the surface of wear plate 611, and both the bolt head and nut have insulated washers above and below slope sheet 607. Wear plate 611 has corresponding bent tabs 616 folded over the vertex between the central and outboard troughs, as shown in FIG. 10b. The major legs of wear plates 610, and 611, and 612 each present an engagement, or bearing surface to coils positioned in either the central or outboard troughs, the size of the leg measured along the slope being sufficient to accommodate the range of coil sizes for which the car is designed.

[0169] As described, in this way thermally insulative material having sufficient structural strength to bear the load of coils is placed directly upon the slope sheets, the assembly so formed being free of flammable materials such as wood or plastic. That is, the non-flammable thermally insulative material is directly in contact with the slope sheets. Unlike the wooden planks, the thermally insulative layer is non-flammable to a temperature of at least 600 F.

[0170] The insulated features of the coil car embodiments of FIGS. 9a, 9b, 10a and 10b, can be applied, with suitable changes in geometry, to others of the examples of coil cars described herein such as coil car 20, 400, or coil car 500 so as to combine the insulated features of coil cars 550 or 600 with the features of coil cars 20, 400 or 500.

[0171] A preferred embodiment has been described in detail and a number of alternatives have been considered. As changes in or additions to the above described embodiments may be made without departing from the nature, spirit or scope of the invention, the invention is not to be limited by or to those details, but only by the appended claims.

Claims

1. A rail road coil car comprising: a trough structure supported by railcar trucks for rolling motion in a longitudinal direction; said trough structure including first, second and third longitudinally aligned side-by-side troughs; each of said first second and third troughs having deck sheeting for carrying coils in said troughs; and at least one of said troughs having a thermally insulative material mounted above the respective deck sheeting therof.

2. The coil car of claim 1 wherein said trough structure includes laterally extending end walls, and said end walls have thermally insulative material mounted thereto.

3. The rail road coil car of claim 2 wherein said end bulkheads each have a face oriented inwardly toward said trough, and said thermal insulation is mounted to said inwardly oriented face.

4. The rail road coil car of claim 3 wherein a liner is mounted to said thermal insulation material, said liner being mounted to face coils carried in said trough structure.

5. The rail road coil car of claim 3 wherein said thermal insulation material is mounted between said inwardly oriented face of said bulkhead and a wear plate.

6. The rail road car of claim 1 wherein said thermal insulation material mounted to said slope sheets is overlain by a liner.

7. The rail road car of claim 6 wherein said thermal insulation material mounted to said slope sheets overlies wooden planking.

8. The rail road car of claim 6 wherein said thermal insulation material mounted to said slope sheets is in direct contact with said slope sheets.

9. The rail road coil car of claim 6 wherein said thermal insulation material meets said slope sheet on planar interface free of intervening layers.

10. The rail road car of claim 6 wherein said thermal insulation material is non-flammable to at least 600 F.

11. A triple trough rail road coil car comprising a trough structure mounted on rail car trucks for rolling operation in a longitudinal direction, said trough structure including first, second and third side-by-side troughs, at least one of said troughs having a pair of opposed inclined slope sheets co-operable to cradle a coil, said slope sheets having non-flammable thermal insulating materials mounted directly thereto.

12. The coil car of claim 11 wherein said thermal insulation material is operable at temperatures at least as high as 600 F.

13. The rail road coil car of claim 11 wherein said trough structure includes a pair of transversely mounted walls defining end bulkheads of said trough structure, and said end bulkheads also have thermal insulation mounted thereto.

14. The rail road coil car of claim 11 wherein said thermal insulation mounted to said slope sheets is overlain by a load bearing liner.

15. The rail road coil car of claim 14 wherein said trough structure includes a pair of transversely mounted walls defining end bulkheads of said trough structure, said end bulkheads also having thermal insulation mounted thereto, and said thermal insulation of each of said end bulkheads is shielded by a wear plate.

16. The rail road coil car of claim 15 wherein said thermal insulation mounted to said slope sheets is operable to at least 600 F., and said thermal insulation mounted to said end bulkheads is also operable to at least 600 F.

17. A triple trough rail road coil car having a trough structure carried upon rail car trucks in a longitudinal rolling direction, said trough structure including three side-by side troughs, at least a first of said troughs having a pair of opposed inclined slope sheets, and a pair of transversely extending end walls defining end bulkheads of said first trough, said slope sheets each being provided with a layer non-flammable structural thermal insulation mounted thereabove, said non-flammable insulation being overlain by a wear plate, each of said end bulkheads being provided with a layer of non-flammable insulation material mounted thereto facing inwardly into said trough, said layer of insulation material mounted to each of said end bulkheads being shielded by a wear plate.

18. The rail road car of claim 18 wherein said insulation material above said slope sheets, and said insulation material mounted to said end bulkheads being non-flammable to at least 600 F.

19. The rail road coil car of claim 18 wherein said non-flammable insulation material lies directly in contact with said slope sheets.

20. The rail road coil car of claim 18 wherein said trough structure is supported by a plurality of cross members mounted along said car, and said trough structure is slung between a pair of side sills whose depth of section exceeds that of said trough.

21. A triple trough rail road coil car comprising a trough structure mounted on rail car trucks for rolling operation in a longitudinal direction, said trough structure including free side-by-side troughs, at least one of said troughs having a pair of opposed inclined slope sheets co-operable to cradle a coil, and a pair of end walls mounted transversely relative to said slope sheets to define end bulkheads of said trough structure, said end bulkheads having thermal insulating materials mounted thereto.

22. A railroad coil car, having a length and a width, said coil car comprising: a pair of first and second end structures each mounted upon a rail car truck; a pair of side sills extending between said end structures; and a trough structure for carrying coils mounted between said side sills; each of said side sills having a top chord, a bottom chord and intermediate structure joining said top and bottom chords, and said coil car having a greater width measured across said top chords of said side sills than across said bottom chords of said side sills; and said trough structure being lined with thermally insulative materials.

23. The railroad coil car of claim 1 wherein said intermediate structure of each of said side sills includes a web extending between said top and bottom chords, and is inclined at an angle from vertical.