Hopper railcar composite partition

According to some embodiments, a railcar comprises at least two hoppers for transporting a commodity. Each hopper comprises a pair of side walls and a floor. The railcar further comprises a composite partition separating the hoppers. The composite partition comprises a frame comprising a first material coupled to the pair of side walls and the floor at a location separating hoppers. The frame comprises a center opening. The frame is configured to provide structural support for structural loads exerted on the pair of side walls and the floor. The composite partition further comprises a composite section comprising a second material coupled to the frame and covering the central opening of the frame. The composite section is configured to withstand loads exerted on the composite section by the commodity transported in the hoppers.

TECHNICAL FIELD OF THE INVENTION

This disclosure relates generally to railcars, and more particularly to a composite partition for use in a hopper railcar.

BACKGROUND

Hopper railcars are used to transport a variety of commodities, including grains, plastic pellets, dried distillers grain, and fertilizers such as potash and fly ash. A hopper railcar typically contains two or more hoppers, although single hopper cars do exist. The number of hoppers chosen for a given hopper railcar may depend on both the commodities to be shipped and the unloading capabilities at the destination location. Multiple hoppers are usually separated by partitions. These partitions function not only to separate the commodities transported within the hoppers, enabling controlled unloading of the commodities, but also to strengthen the structure of the railcar.

SUMMARY

Hopper railcars are used to transport a variety of commodities, including grains, plastic pellets, dried distillers grain, and fertilizers such as potash and fly ash. A hopper railcar typically contains two or more hoppers, although single hopper cars do exist. The number of hoppers chosen for a given hopper railcar may depend on both the commodities to be shipped and the unloading capabilities at the destination location. Multiple hoppers are usually separated by partitions. These partitions function not only to separate the commodities transported within the hoppers, enabling controlled unloading of the commodities, but also to strengthen the structure of the railcar.

The partitions in hopper railcars are subjected to various loads during the operation of the railcars, including structural loads imposed by the railcars travelling over the rails, as well as loads imposed by the commodities, themselves, that are transported within the railcars. These loads tend to arise when the railcars are subjected to longitudinal accelerations and/or decelerations. In the event of a crash, or the use of an emergency brake, the commodity loads imposed on a partition may be large enough to cause the partition to bend and/or buckle, generating a force that may pull the sides of the railcar towards the center of the car. To avoid this situation, manufacturers typically employ partitions of significant weight, typically sufficient to withstand such loads without bending/buckling. However, the significant weight of these partitions may decrease the efficiency of the railcars. For example, the weight of the partitions may result in decreased capacity of the hopper cars, as compared with hopper railcars containing lighter partitions. As another example, the weight of the partitions may result in increased fuel consumption, as compared with hopper railcars containing lighter partitions.

Previous attempts have been made to design hopper railcar partitions using composite materials such that the overall weight of the partitions is decreased, but the load-withstanding capabilities of the partitions are maintained, as compared to partitions formed entirely from steel. However, none of these attempts have proven fully satisfactory. For example, many such attempts have been undertaken as part of manufacturing a composite railcar in which the partitions are permanently bonded to the rest of the railcar body. Unfortunately, this makes repair and/or replacement of a damaged partition difficult or impossible. Additionally, such a partition may not easily be replaced (if it is possible to replace the partition at all), in the event that a different partition, with different structural properties and performance is desired.

This disclosure contemplates a hopper railcar composite partition that addresses one or more of the above issues. The composite partition includes a metal frame, capable of providing structural support to withstand the structural loads experienced by a typical railcar, along with a lighter, composite section, capable of withstanding the loads exerted by typical commodities transported in the railcar. The use of a lighter weight composite section in place of a steel center portion may result in significant weight savings, as compared to a partition composed entirely of steel. This disclosure further contemplates that the composite section of the partition may be mechanically fastened to the metal frame of the partition. In this manner, the composite section of the partition may be easily removed for repair/replacement, while the metal frame may remain in position, continuing to provide structural support to the railcar.

Certain embodiments of the hopper railcar composite partition may provide one or more technical advantages. For example, an embodiment may provide sufficient support to withstand both the structural loads experienced by a typical hopper partition, as well as the loads imposed by typical commodities transported within the hoppers of a hopper railcar, while weighing less than a comparable all-steel partition. As another example, an embodiment may increase the fuel efficiency of a hopper railcar. As another example, an embodiment may provide increased commodity capacity for a hopper railcar. As another example, an embodiment may enable easy replacement/repair of a hopper partition. As a further example, an embodiment may enable customization of a hopper partition based on desired structural properties and performance. Certain embodiments may include none, some, or all of the above technical advantages. One or more other technical advantages may be readily apparent to one skilled in the art from the figures, descriptions, and claims included herein.

DETAILED DESCRIPTION

Embodiments of the present disclosure and its advantages are best understood by referring toFIGS.1through9of the drawings, like numerals being used for like and corresponding parts of the various drawings.

Hopper railcars are used to transport a variety of commodities, including grains, plastic pellets, dried distillers grain, and fertilizers such as potash and fly ash. A hopper railcar typically contains two or more hoppers, although single hopper cars do exist. The number of hoppers chosen for a given hopper railcar may depend on both the commodities to be shipped and the unloading capabilities at the destination location. Multiple hoppers are usually separated by partitions. These partitions function not only to separate the commodities transported within the hoppers, enabling controlled unloading of the commodities, but also to strengthen the structure of the railcar.

The partitions in hopper railcars are subjected to various loads during the operation of the railcars, including structural loads imposed by the railcars travelling over the rails, as well as loads imposed by the commodities, themselves, that are transported within the railcars. These loads tend to arise when the railcars are subjected to longitudinal accelerations and/or decelerations. In the event of high longitudinal accelerations/decelerations of the railcar, the commodity loads imposed on a partition may be large enough to cause the partition to bend and/or buckle, generating a force that may pull the sides of the railcar towards the center of the car. To avoid this situation, manufacturers typically employ partitions of significant weight, typically sufficient to withstand such loads without bending/buckling. However, the significant weight of these partitions may decrease the efficiency of the railcars. For example, the weight of the partitions may result in decreased capacity of the hopper cars, as compared with hopper railcars containing lighter partitions. As another example, the weight of the partitions may result in increased fuel consumption, as compared with hopper railcars containing lighter partitions.

Previous attempts have been made to design hopper railcar partitions using composite materials such that the overall weight of the partitions is decreased, but the load-withstanding capabilities of the partitions are maintained, as compared to partitions formed entirely from steel. However, none of these attempts have proven fully satisfactory. For example, many such attempts have been undertaken as part of manufacturing a composite railcar in which the partitions are permanently bonded to the rest of the railcar body. Unfortunately, this makes repair and/or replacement of a damaged partition difficult or impossible. Additionally, such a partition may not easily be replaced (if it is possible to replace the partition at all), in the event that a different partition, with different structural properties and performance is desired.

This disclosure contemplates a hopper railcar composite partition that addresses one or more of the above issues. The composite partition includes a metal frame, capable of providing structural support to withstand the structural loads experienced by a typical railcar, along with a lighter, composite section, capable of withstanding the loads exerted by typical commodities transported in the railcar. The use of a lighter weight composite section in place of a steel center portion may result in significant weight savings, as compared to a partition composed entirely of steel. This disclosure further contemplates that the composite section of the partition may be mechanically fastened to the metal frame of the partition. In this manner, the composite section of the partition may be easily removed for repair/replacement, while the metal frame may remain in position, continuing to provide structural support to the railcar. The hopper railcar composite partition will be described in further detail usingFIGS.1through9.

FIG.1Aillustrates a hopper railcar10in which hopper railcar composite partition50has been installed. For ease of viewing composite partition50, a portion of the sidewall of hopper railcar10has been removed from the figure. This disclosure contemplates that composite partition50may include a metal frame onto which one or more composite sections may be attached, as described in further detail below. This disclosure additionally contemplates that any number of hopper railcar composite partitions50may be installed in hopper railcar10.

FIGS.1B and1Cillustrate an example composite section100that may be attached to a metal frame to form composite partition50.FIG.1Billustrates a front view of composite section100, whileFIG.1Cillustrates a side view of composite section100, in which composite section100ofFIG.1Bhas been rotated by ninety degrees.

This disclosure contemplates that composite section100may be composed of any material or combination of materials such that composite section100may be capable of withstanding the loads exerted by typical commodities transported in a railcar, while nevertheless being lighter weight than a comparable steel partition. For example, in certain embodiments, composite section100may be composed of varying glass or carbon fibers, cellulose, polymer materials, or other organic or non-organic fibers. As another example, in certain embodiments, composite section100may be composed of a fabric impregnated with resin. In some embodiments, the fiber material may be present in composite section100in one or more forms, such as chopped, woven, or non-woven. In some embodiments, composite section100may additionally include internal framing, or other supporting materials.

This disclosure contemplates that the dimensions and/or composition of the composite section100may be varied across the section, as needed, to withstand the loads and deflections the section may be subjected to. For example, in certain embodiments, the composition of composite section100may be varied and/or the thickness of composite section100may be increased in areas of composite section100that typically experience the greatest strain. Thickness, fiber type and orientation may also be varied to help support the metal frame or other railcar structures.

As an example of the use of varying composition and dimensions for composite section100, in certain embodiments, and as illustrated inFIG.1, composite section100may be composed of a plurality of transverse composite beams105. In other embodiments, beams may be oriented vertically, at an angle, or any other orientation or combination of orientations. Beams may be of various sizes, and beams of different sizes may be used on the same partition. In some embodiments, there may be one beam, while in other embodiments, there may be multiple beams. Beams may have cross-sectional shapes that are rectangular, circular, or any of a number of different shapes or combinations of shapes. In some embodiments, the beam may be one large rectangular member. This disclosure contemplates that, in some embodiments, some or all of beams105may be integrally molded together to form one part. In certain embodiments, and as illustrated inFIG.1, beams105may extend in an outward direction from flat material125. In some embodiments, material125may be laminate. In certain embodiments, beams105may be separated from one another by areas of material125to permit sectioning of composite section100, which may facilitate installation and removal, as described in further detail below, in the discussion ofFIG.6.

The beams illustrated in the example are preform beams, but in particular embodiments the beams may be constructed from a range of materials to achieve the same structural benefit.

In certain embodiments, beams105may be constructed from fabric or layers of fabric, surrounding a structural core. This disclosure contemplates that in certain embodiments, the fabric may be impregnated with resin, as described above, and may be present in one or more forms, such as chopped, woven, or non-woven. In certain embodiments, the layers of fabric surrounding the structural core may be laminated together. This disclosure contemplates that the number of layers and the materials used for the layers may be varied based on both design requirements and cost. For example, other materials that provide less support may be used in regions of composite section100expected to experience lower levels of strain.

This disclosure contemplates that the structural cores of beams105may contain any suitable material. For example, in certain embodiments, the cores may include foam, wood, polymer, or any combination of these materials. In some embodiments, the cores may include internal framing, or other supporting materials, to provide additional structural support.

In some embodiments, vinyl ester resin types may be preferred, but any suitable or thermoplastic resin can be used. Construction may also make partial or complete use of pre-impregnated materials (fibers and resins combined). Processing can be done using open mold wet layup, vacuum infusion, vacuum assisted resin transfer molding (VRTM), resin transfer molding (RTM), compression molding, or any other molding process known to those skilled in the art. The components can be room-temperature cured, oven post cured, or oven cured.

In certain embodiments, top surface115of beams105may be sloped downward, to discourage pieces of the commodity from resting on top surface115. This may be desirable so that minimal amounts of the commodity remain inside the hopper railcar when the railcar is emptied. In addition to top surface115being sloped, this disclosure contemplates that top surface115may also be shaped in any other manner which may discourage the commodity from resting on top surface115. For example, in certain embodiments, top surface115may be curved. In certain embodiments, bottom surface120of beams105may be approximately perpendicular to laminate125. This may be desirable to help maximize the strength of beam105. This disclosure contemplates that the number of beams105, the sizes of beams105, and the orientations of beams105may vary based on the performance desired.

As another example of the use of varying composition and/or dimensions for composite section100, the design may be customized to provide increased energy absorption. As described in further detail below, in the discussion ofFIG.5, the internal beam construction may include curved internal stiffeners to increase energy absorption. In certain embodiments composite section100may contain a bubble structure located around the middle of section100and pointing outward, towards the commodity located in the hopper. In certain such embodiments, the bubble may contain a foam core, or a core of any other suitable material. In some embodiments, the bubble may contain internal stiffening ribs and/or high-shear-strength laminates to provide additional support.

In certain embodiments, the use of custom beams or a bubble structure on composite section100may be desirable in the event of an end impact to a hopper railcar employing a partition50containing composite section100. During such an end impact, the commodity transported within the railcar may push against the beams or bubble. In response, the beams or bubble may deform, thereby absorbing some of the inertial energy of the commodity. In such embodiments, it may be desirable to employ a pair of composite sections100, each containing beams or a bubble structure, so that the beams or bubble structure may be present on both sides of composite partition50, or to employ a single composite section100, with a beam or bubble structure present on both sides of the section. In this manner, depending on which end of the railcar that is impacted, one of the sides of partition50may absorb energy, while the other side may be largely unaffected. In this manner, the use of one or more beams or bubble structures on composite partition50may help to attenuate the peak forces imposed on a railcar containing the partition during end impacts.

This disclosure contemplates that composite section100may contain one or more beams or bubble structures, customizable as desired. This disclosure further contemplates that these beams or bubble structures may be of a variety of different shapes and sizes.

In addition to the use of beams105and bubble structures, as described above, this disclosure contemplates that composite sections100may be shaped in any appropriate manner and may contain any appropriate composite materials. For example, in certain embodiments, rather than being flat, as illustrated inFIG.1, composite section100may be curved or may bow away from the metal frame on which it is attached. Additionally, this disclosure contemplates that composite section100may easily be scaled to accommodate different sized railcars. Due to the flexibility of its design, composite section100may easily be customized to provide support against a range of different loads, many of which may depend on the type of commodity transported. Composite section100may provide such support without compromising the structural integrity of the railcar, which may be maintained by the metal frame portion of composite partition50, as described in further detail below, in the discussion ofFIGS.3and4.

FIG.2presents an isometric view of composite section100, providing additional detail. In particular,FIG.2illustrates the use of metal plates205attached to flange215, located around the outer edge of composite section100, along with fastener holes210extending through metal plates205and flange215. This disclosure contemplates that fastener holes210may be used to attach composite section100to the metal frame of composite partition50, which may itself contain holes at similar locations to those of fastener holes210.

In certain embodiments, flange215may include a section of flat laminate. Flange215may provide a transition from the interior of composite section100to the metal frame to which composite section100may attach. In this manner, flange215may be used to isolate the interior of composite section100from potentially damaging forces and deflections applied by the railcar structure, while nevertheless allowing commodity loads applied to composite section100to distribute to the metal frame.

In certain embodiments, and as illustrated inFIG.2, metal plates205may be attached to flange215at and around the locations of fastener holes210, with each fastener hole210extending through a metal plate205. This disclosure contemplates that each metal plate205may contain any number of fastener holes210. Metal plates205may help to distribute loads generated by the fasteners that are used to fasten composite section100to the metal frame of composite partition50into composite section100, potentially reducing the likelihood that composite section100experiences cracks and/or breaks as a result of such loads.

FIG.3illustrates frame305to which at least one composite section100may be attached to form the hopper railcar composite partition. This disclosure contemplates that frame305may be a metal plate from which a large central portion has been removed, leaving hole/opening315and an outer perimeter of metal surrounding opening315. Composite section100may then be configured to attach to the outer perimeter of frame305and to cover opening315, such that when installed in a typical hopper railcar, composite section100may provide sufficient support to withstand the loads exerted on composite partition50by typical commodities transported in the railcar, while frame315may provide sufficient structural support to withstand the structural loads experienced by the partition.

This disclosure contemplates that opening315may be of any size or shape. For example, in certain embodiments, opening315may be rectangular in shape. In other embodiments, opening315may be elliptical in shape. As another example, in certain embodiments, the area of opening315may make up more than50% of the total area of the shape formed from the outer perimeter of frame305. In some embodiments, the area of opening315may make up more than75% of the total area of the shape formed from the outer perimeter of frame305.

In certain embodiments, frame305may be a steel frame. This disclosure contemplates that frame305is of a sufficient strength to provide support for portions of the side walls, roof, and floor of a standard hopper railcar. Additionally, this disclosure contemplates that frame305is of sufficient strength to withstand loads imposed on composite partition50due to railcar twisting, end impacts, vertical and lateral accelerations, as well as any other forces experienced by the railcar during operation. While described as a metal frame throughout this disclosure, this disclosure contemplates that frame305may be formed from any material of suitable strength to provide support for these above-described loads.

As illustrated inFIG.3, the perimeter of frame305contains a series of fastener holes310. This disclosure contemplates that fastener holes310are located at positions around the perimeter of frame305such that fastener holes210on composite section100align with fastener holes310on frame305, when composite section100is positioned against frame305for attachment. In certain embodiments, frame305may contain a greater number of fastener holes310than composite section100. This may be desirable as fastener holes210may be located at different positions on different composite section100. In such situations the locations and number of fasteners310may be such that both a first composite section100and a second composite section100containing fastener holes210at different locations from the first composite section100may be able to attach to frame305.

FIG.4provides a simplified example illustrating a pair of composite sections100configured to attach to frame305using a set of six fastener holes210on each composite section100. A first composite section100may be attached to a first side of frame305, and a second composite section100may be attached to a second side of frame305. As can be seen, these fastener holes210are positioned on each composite section100such that they align with six fastener holes310positioned around the perimeter of frame305. This disclosure contemplates that composite sections100may be attached to frame305in any suitable manner. For example, in certain embodiments, composite section100may be attached to frame305using bolts, rivets, or any other suitable fasteners. As another example, in certain embodiments, composite section100may be attached to frame305using clamps or pins.

As described above, in the discussion ofFIG.2, composite section100may be attached to frame305along a mounting flange215of composite section100. In certain embodiments, mounting flange215may include a section of flat laminate. Mounting flange215may help to isolate the interior structure of composite section100(e.g., beams105, bubble structures, or any other interior structure) from potentially damaging forces and deflections imposed on frame305from the railcar structure, while nevertheless allowing commodity loads imparted on composite section100to distribute to frame305. In certain embodiments, the design of composite section100and frame305is optimized such that a first failure mode of composite partition50is a failure of the fasteners. In this manner, certain embodiments of composite partition50reduce the chances of damage to composite partition100.

FIG.5illustrates a cross-section of a portion of composite section100that includes two beams105. As can be seen inFIG.5, in certain embodiments, composite section100includes underlayment505, beam outer layers520, core material510, and internal walls515. In certain embodiments, underlayment505may be formed from flat laminate and extend over the entire area of composite section100, such that flange215may correspond to the outer perimeter region of underlayment505. In certain embodiments, underlayment505may be constructed from fiber materials with the fiber orientation optimized to maximize the strength of composite section100. In some embodiments, underlayment505may be constructed from fiber materials with the fiber orientation optimized to control deflection of composite section100in a desired fashion. In certain embodiments, underlayment505may include layers of fiber materials in which the fiber orientations in each layer are optimized to maximize the strength of composite section100and/or control deflection of composite section100in a desired fashion, such that different layers may have different fiber orientations. This disclosure contemplates that in some embodiments, the fiber materials may include fabric impregnated with resin. In some embodiments, the fiber layers of underlayment505may be laminated.

In certain embodiments, beam outer layers520may also be constructed from fiber materials, similar to underlayment505. For example, in certain embodiments, beam outer layers520may be formed from glass or carbon fibers, cellulose, polymer fibers, or other organic or inorganic fibers with the orientations of the fibers optimized to maximize the strength of beams105and/or to control deflection of composite section100in a controlled manner. In some embodiments, beam outer layers520may be constructed from fabric or layers of fabric. This disclosure contemplates that in certain embodiments, the fabric may be impregnated with resin and may be present in one or more forms, such as chopped, woven, or non-woven. In certain embodiments, beam outer layers520may be formed from layers of fabric that are laminated together. This disclosure contemplates that the number of layers and the materials used for the layers may be varied based on both design requirements and cost. For example, other materials which provide less support may be used in regions of composite section100expected to experience lower levels of strain.

This disclosure contemplates that the structural cores510of beams105may include any suitable material. For example, in certain embodiments, the cores may include foam, wood, polymer, or any combination of these materials. In some embodiments, the cores may contain internal framing, to provide additional structural support, such as internal walls515illustrated inFIG.5. This disclosure contemplates that internal walls515may be formed from any material suitable to provide sufficient structural support to beams105. For example, in certain embodiments, internal walls515may be formed from high-shear-strength laminates. In some embodiments, internal walls515may be horizontal walls, extending from underlayment505to beam outer layer520in an approximately perpendicular direction. In certain embodiments, internal walls515may be curved rather than horizontal. For example, in certain embodiments, internal walls515may be “C”-shaped. This may be desirable as it may help to extend the fatigue life of beams105. For example, in the event of an end impact to a hopper railcar employing a partition containing composite section100, the commodity transported within the railcar may push against beams105. In such situations, the presence of “C”-shaped internal walls515may increase the ability of beams105to absorb inertial energy of the commodity due to an increased capacity for deflection, as compared to horizontal internal walls; in such situations, “C”-shaped internal walls515may act as internal springs. In a similar manner, beams105may be constructed in a manner to further increase their energy absorption capabilities, by adding curves to the surface of beams105(i.e., outer layer520).

In certain embodiments, top surface115of beams105may be sloped downward, to discourage pieces of the commodity from resting on top surface115. This may be desirable so that minimal amounts of the commodity remain inside the hopper railcar when the railcar is emptied. In addition to top surface115being sloped, this disclosure contemplates that top surface115may also be shaped in any other manner which may discourage commodity from resting on top surface115. For example, in certain embodiments, top surface115may be curved. In certain embodiments, bottom surface120of beams105may be approximately perpendicular to laminate125. This may be desirable to help maximize the strength of beam105. This disclosure contemplates that the number of beams105, the sizes of beams105, and the orientations of beams105may vary widely based on the performance desired.

In certain embodiments, composite section100may be coated with a coating to protect section100from abrasion damage that may otherwise be inflicted on composite section100by various commodities transported within the hopper railcar in which composite section100is installed. In some embodiments, composite section100may be coated with a coating to protect section100from ultraviolet radiation damage. In some embodiments, the coating may be food grade-rated to allow for the transport of commodities intended for human consumption.

In certain embodiments, composite section100may be composed of one or more pieces.FIG.6illustrates a portion of a composite section100composed of multiple pieces. The use of a composite section100composed of multiple pieces may be desirable to help facilitate installation, repair, and/or removal of composite section100from a hopper railcar. For example, in certain embodiments, the hopper railcars into which composite partitions may be installed may be covered hopper railcars. Such railcars have a roof to protect the commodity being transported within the railcar from the external environment. These roofs may contain one or more openings, such as a trough or a smaller opening. Different hopper railcars may have roof openings of various sizes and shapes. In such situations, it may not be possible to fit the entire composite section100through such a roof opening when installing and/or removing composite section100from the railcar. Accordingly, certain embodiments contemplate forming composite section100from a set of smaller pieces. For example, in certain embodiments, the flat areas of laminate125between adjacent beams105may facilitate sectioning of beams105, such that each piece of composite section100may contain one or more beams105. This disclosure contemplates that these smaller pieces may be configured to be inserted into and/or removed from the restricted openings in the roofs of covered hopper railcars. In this manner, in certain embodiments, composite section100may be inserted into a hopper railcar piece by piece. After the pieces of composite section100have been inserted into the hopper railcar, in certain embodiments, they may be mechanically fastened or bonded together to form composite section100, which may then be attached to frame305. In certain embodiments, secondary plates605and610may be installed over the joints between adjacent pieces of composite section100to provide enhanced strength at the joints. This disclosure contemplates that secondary plates605and610may be formed from metal or any other material of suitable strength. In other embodiments, after the pieces of composite section100have been inserted into the hopper railcar, the pieces may be individually attached to frame305. This disclosure contemplates that each of the pieces of composite section100may be similar to one another or may be different from one another. For example, in certain embodiments, different pieces may be of different sizes, contain different numbers of beams105, be composed on different materials, and/or have other different properties from one another.

In certain embodiments, the use of a composite section100composed of multiple pieces may be desirable to facilitate repair of a damaged beam105. In such embodiments, rather than removing the entire composite section100to repair the damaged beam, the piece of composite section100containing the damaged beam may be removed from the section and replaced with a new piece. The ability to remove pieces of composite section100rather than the entire section may also be desirable in situations in which it may be desirable to modify composite section100for improved performance, reduced cost, reduced weight, or to provide different coatings for different commodities.

WhileFIGS.5and6illustrate a composite section100containing beams105on only one side of the section, this disclosure contemplates that, in certain embodiments, composite section100may contain beams105on both sides, as illustrated inFIG.7. In such embodiments, a single composite section100may be attached to frame305to form composite partition50, rather than a pair of composite sections.

FIG.8presents a flowchart illustrating a method by which composite partition50may be manufactured. In step805, metal frame305is formed. In certain embodiments, metal frame305may be formed from a solid piece of metal from which an inner piece of metal is removed to form opening315. In some embodiments, metal frame305may be formed by pouring liquid metal into a form of a suitable shape and size to produce metal frame305. In step810, holes are drilled into metal frame305to form fastener holes310. This disclosure contemplates that fastener holes310may be used to attach composite sections100to metal frame305.

Composite sections100are, themselves, formed in step815. In certain embodiments forming a composite section100includes forming underlayment505and forming beam core material510. In certain embodiments, underlayment505may be formed from flat laminate and extend over the entire area of composite section100, such that flange215may correspond to the outer perimeter region of underlayment505. In certain embodiments, underlayment505may be constructed from fiber materials with the fiber orientation optimized to maximize the strength of composite section100. In some embodiments, underlayment505may be constructed from fiber materials with the fiber orientation optimized to control deflection of composite section100in a desired fashion. In certain embodiments, underlayment505may include layers of fiber materials in which the fiber orientations in each layer are optimized to maximize the strength of composite section100and/or control deflection of composite section100in a desired fashion, such that different layers may have different fiber orientations. This disclosure contemplates that in some embodiments, the fiber materials may include fabric impregnated with resin.

In certain embodiments, beam core material510may include foam, wood, polymer, or any other suitable material or combination of materials. In some embodiments, the cores may include internal framing515, or other supporting materials, to provide additional structural support.

In certain embodiments, beam outer layers520may be attached to beam core material510and the resulting beams105may then be attached to underlayment505. In some embodiments, beam core material510may first be attached to underlayment505and then beam outer layers520may be attached to beam core material510. For example, in certain embodiments, beam outer layers520may include a continuous piece of material that may be placed on top of both beam core material510and underlayment505. This disclosure contemplates that beam outer layers520may be formed from any suitable material. For example, in certain embodiments, beam outer layers520may be formed from fiber materials, similar to underlayment505. For example, in certain embodiments, beam outer layers520may be formed from glass or carbon fibers, cellulose, or polymer fibers, with the orientations of the fibers optimized to maximize the strength of beams105and/or to control deflection of composite section100in a controlled manner. In some embodiments, beam outer layers520may be constructed from fabric or layers of fabric. This disclosure contemplates that in certain embodiments, the fabric may be impregnated with resin and may be present in one or more forms, such as chopped, woven, or non-woven. In certain embodiments, beam outer layers520may be formed from layers of fabric that are laminated together.

In step820, holes are drilled into flange215of composite section100to create fastener holes210. This disclosure contemplates that fastener holes210may be used to attach composite section100to metal frame305.

Finally, in certain embodiments, composite section100may be sprayed with a coating to protect section100from abrasion damage that may otherwise be inflicted on composite section100by various commodities transported within the hopper railcar in which composite section100is installed. In some embodiments, composite section100may be coated with a coating to protect section100from ultraviolet radiation damage. In some embodiments, the coating may be food grade-rated to allow for the transport of commodities intended for human consumption.

Modifications, additions, or omissions may be made to method800depicted inFIG.8. Method800may include more, fewer, or other steps. For example, steps may be performed in parallel or in any suitable order.

FIG.9presents a flowchart illustrating a method by which an embodiment of composite partition50that includes a composite section100composed of multiple pieces may be installed in a typical hopper car10. In step905metal frame305is attached to the inside of hopper car10. This disclosure contemplates that metal frame305may be attached to the inside of hopper car10in any suitable manner. For example, in certain embodiments, metal frame305may be attached to the inside of hopper car10by welding portions of the outer perimeter of metal frame305to the inside of hopper car10during the manufacture of hopper car10.

In step910, individual pieces of composite section100are inserted into hopper car10, through an opening in the roof of hopper car10. In step915, the individual pieces of composite section100may be fastened together to form composite section100. In certain embodiments, the pieces of composite section100may be mechanically fastened together to form composite section100. In some embodiments, the pieces of composite section100may be bonded together to form composite section100. In step920, secondary plates605and610may be installed over the joints between adjacent pieces of composite section100, to provide enhanced strength at these joints. Finally, in step925, composite section100may be attached to frame305. This disclosure contemplates that composite sections100may be attached to frame305in any suitable manner. For example, in certain embodiments, composite section100may be attached to frame305using bolts, rivets, or any other suitable fasteners. As another example, in certain embodiments, composite section100may be attached to frame305using clamps or pins. This disclosure additionally contemplates that, rather than fastening the individual pieces of composite section100together prior to fastening composite section100to metal frame305, in certain embodiments, after the pieces of composite section100have been inserted into the hopper railcar, the pieces may be individually attached to frame305.

Modifications, additions, or omissions may be made to method900depicted inFIG.9. Method900may include more, fewer, or other steps. For example, steps may be performed in parallel or in any suitable order.

Although the present disclosure includes several embodiments, a myriad of changes, variations, alterations, transformations, and modifications may be suggested to one skilled in the art, and it is intended that the present disclosure encompass such changes, variations, alterations, transformations, and modifications as falling within the scope of the appended claims.