Patent Abstract:
A railroad track tie comprises a body formed at least partially of polymeric material, and a reinforcement totally encapsulated within the body, wherein there is at least one opening through the reinforcement with polymeric material therein.

Full Description:
[0001]     This application is related to application Ser. No. 10/278,754 filed Oct. 22, 2002; application Ser. No. 10/346,204 filed Jan. 15, 2003; application Ser. No. 10/927,569 filed Aug. 25, 2004; and application Ser. No. 10/997,025, filed Nov. 22, 2004. All of the aforementioned applications are incorporated herein by reference. 
     
    
     BACKGROUND  
       [0002]     A tie is a beam like structure that provides support for a track, and in the case of railroad tracks, couples or ties the rails of a train track. As  FIG. 1A  illustrates, which is taken from the U.S. Pat. No. 6,336,265 to Niedermair, ground based railway cross ties  100  are positioned on and supported by a rail bed  102  that is mostly comprised of crushed gravel that forms a ballast base  104  that supports the entire cross tie  100 . In use, the ground based cross ties  100  are positioned in a parallel and spaced apart configuration partially submerged within the ballast  104  so that the upper surface  106  of each cross tie  100  is exposed, and the rest of their body is securely grounded and is supported by the ballast  104 . Two railroad track rails  108  are secured in place to the cross ties  100  in a well known conventional manner, such as by spikes  110 .  
         [0003]      FIG. 1B  illustrates a typical wooden cross tie  120  used on a railway bridge. The tie  120  rests on two steel girders  122  rather than being submerged within ballast  104 . Conventionally, bridge rails  108  are placed or positioned such that the girder span (or length) L G  between the girders  122  is equal to or greater than the rail span L R  between the two rails  108 . In other words, a horizontal distance  123  separates the outer edges  125  of the rails  108  from the inner top surface edges  127  of the girders  122 . The wider girder span L G  creates greater stability and therefore supports and protects (prevents) the train from flipping over from centrifugal forces during turns. The horizontal distance  123  between the rails  108  and the girders  122  (or the girder span L G ) depends on engineering and construction constraints. For example, a bridge may have electric or other utility pipes that extend along the length of the bridge, and which may be laid in between the girders  122 . In such an instance, the girder span L G  (and hence the horizontal separation  123 ) would have to be sufficiently long to accommodate the placement of the utility pipes. On the other hand, a bridge might not have any utility lines or pipes, which would allow for a shorter horizontal separation distance  123  between rails  108  and girders  122 .  
         [0004]     As illustrated in  FIGS. 1C , under heavy load conditions, the ties  120  must withstand horizontal forces, which are generally parallel along the axis of the beam  120 . The horizontal forces may include tensile forces such as those indicated by arrow A and arrow B, and/or compression forces indicated by arrow C and arrow D. The tensile and compression forces can cause horizontal shearing  124  that are generally parallel along the axis of the beam  120 . As  FIG. 1D  illustrates, under heavy load conditions, the ties  120  must in addition withstand vertical forces that are normal to the beam  120 , such as bending moments, which can cause vertical shearing  126  perpendicular to the beam  120 . As illustrated, the shearing  126  is at or near where the actual load is experienced by the beam  120 , which is proximal to the outer edges  125  of the rails  108  and the inner top surface edges  127  of the girders  122 , where an unsupported distance  123  between the these two edges exists. Of course, the beam  120  need not bend to shear vertically. As stated in Chambers Dictionary of Science and Technology, volume 2, 1974, shearing is a “type of deformation in which parallel planes in a body remain parallel but are relatively displaced in a direction parallel to themselves; in fact, there is a tendency for adjacent planes to slide over each other. For example, a rectangle, if subjected to a shearing force parallel to one side, becomes a parallelogram. The bending moment at any imaginary transverse section of a beam is equal to the algebraic sum of the moments of all the forces to either side of the section of the beam.” Therefore, bridge cross ties  120  may differ in construction compared with ground based cross ties in that bridge cross ties must have a higher structural strength and integrity to withstand and oppose all the tensile, compression, shear, and torsion forces and bending moments that are exerted by a heavy load. With ground based cross ties, the ballast  104  bears and opposes some of these forces.  
         [0005]     Most conventional ties (bridge or ground) have been formed from hardwood, concrete, or steel. Conventional hardwoods present disadvantages in that given their scarcity, they are expensive to produce and susceptible to decay. This is particularly true in marine environments where hardwood bridge cross ties are used on bridges that span over bodies of water. Hardwood cross ties can be treated with creosote to prolong their life span. However, creosote is toxic, which can result in potential environmental hazards.  
         [0006]     Previous attempts have been made to develop a substitute for the conventional wooden ties, such as by manufacturing cross ties from synthetic resins, concrete, or steel. Although synthetic resins may be used as ground based cross ties, where a ballast exists as a major load bearing support, they cannot be used as bridge cross ties where no rail bed exists. Regarding concrete and steel ties, they are heavy and awkward to maneuver, difficult to install (must provide special openings for spikes), and concrete ties shatter upon impact. Both concrete and steel ties are expensive to make and repair. Furthermore, steel, standing either alone or as reinforcement in porous concrete, is subject to corrosion.  
         [0007]     Other attempts have been made to provide long lasting ties. Reference is made to U.S. Pat. Nos. 6,336,265 and 4,150,790. Regrettably, these ties suffer from one or more disadvantages such as low bending strength, low resistance to impact loading, short life, difficult installation and/or lack of durability.  
       SUMMARY  
       [0008]     The present invention provides a tie that is suitable for many uses including railroad tracks over bridges, and overcomes disadvantages of prior art ties. In one version of the invention, a tie suitable for use for a railroad track comprises a substantially rectangular prismatic body having dimensions of about the same size as conventional ties, which means it has a length of from about 6 to about 14 feet, a width of about 6 to about 16 inches, and a depth of from about 6 to about 16 inches. The body comprises a polymeric material and has substantially completely embedded therein an elongated reinforcement structure. There is at least one opening through the reinforcement structure with polymeric material therein.  
         [0009]     The tie is suitable for use for a vehicle track comprising at least one rail, a plurality of elongated ties supporting the rail, and a plurality of spikes holding the rail to the tie. Typically, there are two parallel rails, such as in the case of a railroad track.  
         [0010]     In a preferred version of the invention, the reinforcement structure comprises a top flange and a bottom flange connected by a shear plate, wherein the opening is through the shear plate. 
     
    
     DRAWINGS  
       [0011]     These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, in which like reference character(s) present corresponding parts throughout, where:  
         [0012]      FIG. 1A  is an exemplary illustration of a prior art railroad track;  
         [0013]      FIG. 1B  is an exemplary illustration of a prior art bridge cross tie;  
         [0014]      FIG. 1C  is an exemplary illustration of a prior art bridge cross tie under heavy load conditions with applied horizontal forces, causing horizontal shearing;  
         [0015]      FIG. 1D  is an exemplary illustration of a prior art bridge cross tie under heavy load conditions with applied vertical forces, causing vertical shearing;  
         [0016]      FIG. 2  illustrates a railroad cross tie comprising a reinforcement encapsulated inside a body, in accordance with the present invention;  
         [0017]      FIGS. 3A and 3B  are perspective illustrations of an I-beam type reinforcement encapsulated inside a body, in accordance with the present invention;  
         [0018]      FIGS. 3C  to  3 H are cross-sectional and top or plan view illustrations of different embodiments of I-beam like reinforcement, in accordance with the present invention;  
         [0019]      FIGS. 4A  to  4 C are illustrations of a three sided reinforcement encapsulated inside a body, with  FIGS. 4A and 4B  illustrating the perspective view, and  FIG. 4C  illustrating the cross-sectional and plan or top views, all in accordance with the present invention;  
         [0020]      FIGS. 5A  to  5 D are illustrations of a four sided reinforcement encapsulated inside a body, with  FIGS. 5A and 5C  illustrating the perspective view,  FIG. 5B  illustrating the cross-sectional view normal to the reinforcement, and  FIG. 5D  illustrating the cross-sectional view along the axis of the reinforcement and the top or plan view, all in accordance with the present invention;  
         [0021]      FIGS. 6A  to  6 D are exemplary illustration of another four sided reinforcement encapsulated inside a body, with  FIGS. 6A and 6C  illustrating the perspective view,  FIG. 6B  illustrating the cross-sectional view normal to the reinforcement, and  FIG. 6D  illustrating the cross-sectional view along the axis of the reinforcement and the top or plan view, all in accordance with the present invention. 
     
    
     DESCRIPTION  
       [0022]     Most conventional ties are made of very strong hardwood timbers, which are very scarce, expensive to produce, and susceptible to decay. The present invention provides ties that are strong, easily installed, environmentally sound, and more durable, and are particularly adapted for use as bridge ties. Ties according to the present invention in general comprise a reinforcement structure that is completely encapsulated inside a polymeric body. The structures of the present invention are configured to provide sufficient strength to withstand the tensile, compression, shear, and torsion forces and bending moments that are exerted by a heavy load. The structures are also configured for efficient metal usage and weight.  
         [0023]     The encapsulation of the reinforcement structure within the polymeric body in accordance with the present invention contributes to the longevity of the ties by protecting the metal from corrosive intrusions. The reinforcement structure provides at least a substantial portion of the structural strength, integrity, and stability. In other words, the reinforcement structure functions to provide the structural core to resist bending and shear loads. The polymeric body casing provides the bulk of the mass needed to which other members can be affixed, non-limiting example of which are rails and spikes, to allow the encapsulated structure to function as tie. The casing also provides a non-conductive mass to prevent an electrical current from passing from one steel rail to another (prevents cross circuiting), if the tie is used in as a railway cross tie. It is an industry standard practice to use the steel rails on a railway to send electrical signal to traffic control systems.  
         [0024]      FIG. 2  is an exemplary cross-sectional illustration, taken along the longitudinal axis of a tie  200  according to the present invention, which is comprised of a metallic (preferably weldable steel or steel alloy) reinforcement structure  202  encapsulated, and preferably centrally located in all dimensions, inside a body  204 . Preferably, the body  204  comprises a polymeric material, i.e., a substance made of many repeating chemical units or molecules. As illustrated, the tie  200  rests on two steel girders  122  in a conventional manner, where the rails  108  are positioned such that the girder span (or length) L G  between the girders  122  is in general equal to or greater than the rail span L R  between the two rails  108 . In other words, the outer edges  125  of the rails  108  are in general near the inner top surface edges  127  of the girders  122 , with a separation distance  123  between the two edges as illustrated. Under heavy load conditions, the tie  200  can withstand tensile, compression, shear, and torsion forces and bending moments because of reinforcement structure  202 , which comprises an axial or longitudinal upper flange  206  and lower flange  208 , and coupled shear plates  210  and  211  (also known as web plates).  
         [0025]     The use of shear plates  210  and  211  in combination with the flanges  206  and  208  provides great strength to the tie  200 . The use of web or shear plates  210  and  211  allow for the connection of the flanges together, which in turn form a rigid structural core to resist bending moments, shear and other forces. That is, flanges  206  and  208  aid in supporting the load, and the shear plates  210  and  211  help prevent the flanges  206  and  208  from bending vertically normal to the top surface of the beam  200  or moving horizontally relative to the beam  200  due tensile, compression, shear, and torsion forces and bending moments that are applied to the beam  200  when under heavy load. The flanges  206  and  208  without their connection to each other by the web or shear plates  210  and  211  do not provide as much strength.  
         [0026]     In general, to prevent horizontal shearing, the shear plates  210  and  211  provide opposing tensile forces indicated by the arrows E and G against the load tensile forces indicated by the arrows A and B. Furthermore, the same shear plates  210  and  211  also facilitate in providing opposing compression forces indicated by the arrows F and H against the load compression forces C and D.  
         [0027]     In particular, to prevent vertical shearing, the shear plates  211  span across the entire underneath width of each rail  108 , including their inner edges  129  and outer edges  125 , with a shear plate  211  length that also spans over and includes at least the inner edges  127  of the top surfaces of the girders  122 . However, it is preferable that the length of the shear plates  211  extend to include at least one half of the top surface of the girders  122 , and most preferable if the length of the shear plate  211  covers all of the top surface of the girders  122 . This type of juxtaposing of the shear plates  211  in relation to the rails  108  and the girders  122  provides support, and opposes vertical shearing forces against load vertical shearing that generally occur near inner edges  127  of girders  122 .  
         [0028]     The use of spaced apart web or shear plates  210  and  211  in combination with the flanges  206  and  208  also facilitates efficient material usage and lower structural weight for the tie  200 . The spacing  212  between all the web or shear plates  210  and  211  can vary depending on the size of the flanges  206  and  208  being used for a particular application.  
         [0029]     Injection molding techniques preferably are used to encapsulate the structure  202  inside the body  204 . The spacing  212  between all the shear plates  210  and  211  allow injected material inside the mold to converge from both sides of the structure  202  to interlock, bind and firmly grasp the structure  202 , providing greater structural integrity for the body  204 . The body  204  encapsulating the frame  202  protects it from the outside environment, provides the required bulk (without any negligible addition of weight) to enable the frame  202  to rest on the girders  122 , and absorbs (dampens) vertical vibration between the rails  108  and the girders  122  due to passing heavy loads. In addition, the use of spaced plates  210  and  211 , and the body  204  lowers the overall weight of the beam  200 , facilitating its easier handling. Furthermore, the reinforced ties  202  inside the body  204  are in general installed in the same manner as wood ties by using spikes  110 , but have the added benefit that they do not split, which may be the case for some wood tie.  
         [0030]     The present invention provides various embodiments in terms of reinforcement  202  for a tie, the differences of which are mostly related to the number, size, and shape of the shear or web plates, the flanges, and the configuration or arrangement of the shear or web plates in relations to each other and the flanges. The paragraphs that follow describe in detail the various embodiments in terms of different reinforcements used for a tie in accordance with the present invention, including the use of an I-beam like frame, and frames with different cross-sectional geometry, the nonlimiting examples of which may include three or more sided frames (e.g., triangles, quadrilaterals such as squares, rectangles, trapezoid, or circular, cylindrical, prismatic, etc).  
         [0031]     A typical railroad tie according to the present invention has a length of about six feet to about fourteen feet, a width from about six to about sixteen inches, and a depth from about six to about sixteen inches. It generally is in the shape of a rectangular or square prism, i.e., a vertical cross-section through the railroad tie  200  yields a rectangular or square.  
         [0032]      FIGS. 3A  to  3 H are exemplary illustration of I-beam like frames with different flanges and shear plate constructions that vary in number, size, and shapes. A commonality between all however, is the fact that the shear or web plates for all the I-beam frame ties are aligned parallel along a single vertical plane passing through the midpoint of the tie width  314  (illustrated in  FIG. 3B ). As  FIGS. 3A and 3B  illustrate, the tie  300  is comprised of a structure  302  encapsulated in body  204 . The I-beam structure  302  includes an upper flange  206 , which is comprised of two axial or longitudinal bars  308  and  312  and a lower flange  208 , which is comprised of two axial or longitudinal bars  304  and  306 . Coupling the upper flange  206  to the lower flange  208  are web or shear plates  310  and  211 , which are sandwiched between the pairs of bars  308  and  312  at an upper proximal end of the plates  310  and  211 , and pairs of bars  304  and  306  at a lower proximal ends of the plates  310  and  211 . Plates  310  and  211  are welded to the flanges  206  and  208  in locations that can provide the optimum strength, weight, and bulk for the structure  302 , with appropriate spacing  212  created between all the plates  310  and  211  for optimal curing of later injected material (using injection molding techniques, described below).  
         [0033]     A completely fabricated structure  302  may be placed inside a mold to be encapsulated within body  204  using injection-molding techniques. The interior chamber of the mold may be configured to be commensurate with the required parameters of a typical tie. The structure  302  is intentionally placed in the mold cavity to allow extruded material to evenly be distributed on all sides of the structure  302 , and through the spacing  212  for interlocking or grasp between the structure  302  and the extruded material, after the material is cured. As illustrated in  FIG. 3B , the structure  302  is placed in the mold (not shown) so that when the material encapsulates it, the structure  302  is fixed in the midpoint of the encapsulating body  204  width  314 . This allows the insertion of spikes  110  through the beam  300 , close to the body of the structure  302  for a more secure connection a track  108 , and further provides a balanced beam  300  in that the beam  300  is not tilted. The height  316 , width  314 , and length of the beam  300  may be varied.  
         [0034]     Injection molding uses equipment similar to that for die casting, in that a precision mold of desired shape is clamped shut, and melted material (for example, from palletized plastics) is forced into the cavity between the mold and the structure  302  that is placed inside the mold. The exemplary palletized plastic material is fed into a heated chamber, or barrel, by a large, slowly rotating mechanism, and is melted. When a sufficient quantity to fill the mold cavity has been prepared, the rotating mechanism is moved axially under high pressure to extrude the melted material into the mold cavity. Some molds may have channels through which coolant is circulated to remove heat and to chill the plastics. When the plastic has cooled sufficiently, the mold is unclamped (or opened), and the molding is either forced out by strategically located ejectors or simply forcefully removed (depending on the type of mold being used.) During cooling and removal, material for the next part is plasticized within the barrel, ready for the cycle to be repeated. For further details of this process and suitable materials for the polymeric body, see U.S. Pat. Nos. 6,244,014 and 6,412,431, all to Barmakian, the entire disclosures of which are incorporated herein by reference. A preferred plastic material for body  204  is recycled polyethylene that contains at least 96% to 98% polyethylene film for lubricity and flexibility.  
         [0035]      FIG. 3C  is an exemplary illustration of the beam  300  in the cross-sectional views normal to the axial length indicated by the reference  320 , along the axial length  322 , and the plan or top view  324  taken along the axial length. The nonlimiting exemplary dimensions of the body  204  may include width  314  of about ten inches, a height  316  of about ten inches, and a length of about ten feet. As to the nonlimiting exemplary dimensions of the reinforcement  302 , the bars may have an approximate length  323  of about nine feet and eight inches, with a diameter of approximately one-inch. The top and bottom bars may be approximately positioned one inch from the respective top and the bottom surfaces of the body  204 . The shear plates  310  may have a nonlimting, exemplary, approximate average thickness  315  of about one-fourth (quarter) inch, with height  311  of about seven and one half inches, and width  313  of about eight inches. The length dimension  313  of the shear plates  211  must be such that the plates span across the entire underneath width of a rail  108 , including the inner edge  129  and outer edge  125 , with a shear plate  211  length  313  that also spans over and includes at least the inner edge  127  of the top surface of the girder  122 . Therefore, the length  313  of the shear plates  211  depends on the separation distance  123  between the outer edge  125  of the rails  108  and the inner top surface edge  127  of the girders  122 . As mentioned above, this separation  123  is based on engineering and construction constraints, which may vary between zero inches to three feet. Accordingly, the length  313  of the shear plate  211  must be extended commensurately to accommodate for the separation distance  123 . Nevertheless, a nonlimiting, exemplary length  313  of the shear plate  211  may start from about four to six inches, and span across the distance  123 . The height  311  and the thickness  315  of the shear plates  211  may be the same as other shear plates. In general, the spacing  212  between all the shear plates  310  and  211  may be about 2 inches. A nonlimiting example of material used for the structure  302  may include weldable steel.  
         [0036]      FIG. 3D  is an exemplary illustration of another embodiment of the I-beam  300  illustrated in  FIGS. 3A and 3B  in the cross-sectional views normal to the axial length  330 , along the axial length  332 , and the plan or top view  334  taken along the axial length of the beam. In this embodiment however, the I-beam structure  302  includes an upper flange  206 , which is comprised of one axial or longitudinal bar  336  and a lower flange  208 , which is comprised of one axial or longitudinal bar  338 . Coupling the upper axial bar  336  to the lower axial bar  338  is a set of web or shear plates  310  and  211 . Plates  310  and  211  are welded to the axial bars  336  and  338  in locations that can provide the optimum strength, weight, and bulk for the structure  302 , with appropriate spacing  212  created between all the plates  310  and  211  for optimal curing of later injected material.  
         [0037]      FIG. 3E  is an exemplary illustration of another embodiment of the I-beam  300  illustrated in  FIGS. 3A and 3B  in the cross-sectional views normal to the axial length  340 , along the axial length  342 , and the plan or top view  344  taken along the axial length of the beam. In this embodiment however, the I-beam structure  302  includes respective upper and lower axial or longitudinal bars  346  and  348  with cross sectional configurations that are substantially quadrilateral.  
         [0038]      FIG. 3F  is an exemplary illustration of yet another embodiment of the I-beam  300  illustrated in  FIGS. 3A and 3B  in the cross-sectional views normal to the axial length  350 , along the axial length  352 , and the plan or top view  354  taken along the axial length of the beam. In this embodiment however, the I-beam structure  302  includes web or shear plates  310  that is continuous along the longitudinal axis of the beam, with opening  213 .  
         [0039]      FIG. 3G  is an exemplary illustration of still another embodiment of the I-beam  300  illustrated in  FIGS. 3A and 3B  in the cross-sectional views normal to the axial length  360 , along the axial length  362 , and the plan or top view  364  taken along the axial length of the beam. In this embodiment however, the I-beam structure  302  includes respective upper and lower axial or longitudinal flanges  366  and  368 , that are substantially flat. In addition, the structure  302  includes web or shear plate  310  that is continuous along the longitudinal axis of the beam, and has openings  213 .  
         [0040]      FIG. 3H  is an exemplary illustration of yet another embodiment of the I-beam  300  illustrated in  FIGS. 3A and 3B  in the cross-sectional views normal to the axial length  370 , along the axial length  372 , and the plan or top view  374  taken along the axial length of the beam. In this embodiment however, the I-beam structure  302  has no flanges or bars, and functions as a web or shear plate  310  with openings  213 .  
         [0041]      FIGS. 4A  to  4 C are exemplary illustration of a three sided frame structure, in accordance with the present invention. Although not illustrated for brevity, it should be understood that like the previously illustrated I-beam frames  302  in all the  FIGS. 3A  to  3 H, the three sided frame structure  402  may also be comprised of different flanges and web or shear plate constructions that vary in number, size, and shapes, similar to those illustrated in  FIGS. 3A  to  3 H. In fact, each of the three sides of the triangular structure  402  may be constructed by using any combinations and or permutations of the above-described structure  302 . The three sided structure  402  has the added advantage in that it provides further stability for the beam  400  by dividing the applied load stresses along its lower wider base. However, the exterior body  204  dimensions remain the same, commensurate with industry standard practices where the beams are to be used.  
         [0042]     As  FIGS. 4A and 4B  illustrate, the tie  400  is comprised of a structure  402  that has a triangular cross section, encapsulated in body  204 . The three corners of the triangular beam structure  402  include a pair of axial or longitudinal bars  408  and  412  that form the first corner, and two axial or longitudinal bars  404  and  406  that form the respective second and third corners of the triangle. The three sides of the triangular beam structure  402  include two sets of laterally inclined web or shear plates  410  and  418  that form the respective first and the second sides, and a bottom web or shear plates  416 , which are connected parallel to the ground, forming the third side of the triangular frame  402 .  
         [0043]     The first corner pair of bars  408  and  412  are coupled to the second corner bar  404  by the first set of laterally inclined web or shear plates  410 , and are further coupled to the third corner bar  406  by a second set of laterally inclined web or shear plates  418 . The respective first and second set of laterally inclined web or shear plates  410  and  418  have opposing slopes, and each plate within its respective set is coupled so to allow a space  212  between the plates. The respective second and third corners  404  and  406  are coupled by the bottom web or shear plates  416 , which are parallel to the ground, and are also coupled so to allow a space  212  between the plates  416 .  
         [0044]     The triangular beam structure  402  further includes at least two vertically oriented web or shear plates  211 . The vertical web or shear plates  211  are generally positioned such that they fall underneath the rails  108  during track assembly, and are aligned along a vertical plane passing through the midpoint of the cross tie width  440  (illustrated in  FIG. 4B ). The use of vertical web or shear plates  211  rather than the laterally inclined plates  410  or  418  underneath the tracks  108  allow spikes  110  to be passed through the beam  400 , close to the upper bars  408  and  412  for a secure connection. The use of inclined web plates  410  or  412  underneath the rails  108  would block the spikes  110 . In addition, the web or shear plates  211  provide augmented resistance to vertical compressive loading of the cushion beam in regions between the bars  404  and  406 . The upper edges of the vertical plates  211  are coupled to the axial pair  408  and  412 , and the lower edges are coupled to the bottom parallel plates  416 . As best illustrated in  FIG. 4B , the web or shear plates  211  are extended longitudinally, spanning a number of web or shear plates  416 . Although not illustrated, plates  211  need not be a single solid unit, but can be comprised of openings similar to those illustrated in  FIGS. 3F  to  3 H.  
         [0045]     All the plates are welded to their respective bars (or the bottom parallel plates in the case of the plates  211 ) at locations that can provide the optimum strength, weight, and bulk for the structure  402 , with appropriate spacing  212  created between the plates for optimal curing of later injected material. A completely fabricated structure  402  may be placed inside a mold to be encapsulated within a material using injection-molding techniques to form body  204 , as described above in relation to  FIGS. 3A  to  3 H.  FIG. 4C  is an exemplary illustration of the beam  400  in the cross-sectional views normal to the axial length indicated by the reference  430 , along the axial length  432 , and the plan or top view  434  taken along the axial length of the beam  400 .  
         [0046]      FIGS. 5A  to  5 D are exemplary illustration of a four sided frame structure  502 , in accordance with the present invention. Although not illustrated for brevity, it should be understood that like the previously illustrated I-beam frames  302  in all the  FIGS. 3A  to  3 H, the four sided frame structure  502  may also be comprised of different flanges and web or shear plate constructions that vary in number, size, and shapes, similar to those illustrated in  FIGS. 3A  to  3 H. In fact, each of the four sides of the quadrilateral structure  502  may be constructed by using any combinations and or permutations of the above-described structure  302 . The four sided structure  502  has the added advantage in that it provides further strength and stability for the beam  500  by dividing the applied load stresses along its four bars, and like its three sided counterpart, it is also stable. However, the exterior body  204  dimensions remain the same, commensurate with industry standard practices where the beams are to be used.  
         [0047]     As  FIGS. 5A  to  5 C illustrate, the tie  500  is comprised of a structure  502  that has a quadrilateral cross section, encapsulated in body  204 . The quadrilateral structure  502  includes two upper and two lower flanges, each of which may be comprised of one or more axial or longitudinal bars. As best illustrated in  FIG. 5B , the four corners A, B, C, and D of the quadrilateral beam structure  502  include a pair of axial or longitudinal bars  504  and  506  that form the first corner A, second pair of axial or longitudinal bars  508  and  512  that form the second corner B, a third pair of axial or longitudinal bars  516  and  518  that form the third corner C, and finally a fourth pair of bars  520  and  514  that form the last or the fourth corner D of the quadrilateral frame  502 .  
         [0048]     Coupling the corner “A” bars  504  and  506  to the corner “D” bars  520  and  514  are web or shear plates  510  and a first set of plates  211 , which are sandwiched between the pairs of bars  520  and  514  at one end of the plates  510  and  211 , and pairs of bars  504  and  506  at the other end of the plates  510  and  211 . Coupling the corner “B” bars  512  and  508  to the corner “C” bars  518  and  516  are web or shear plates  552  and a second set of plates  211 , which are also sandwiched between the pairs of bars  516  and  518  at one end of the plates  552 , and pairs of bars  512  and  508  at the other end of the plates  552  and  211 .  
         [0049]     Coupling the corner “A” bars  506  and  504  to the corner “B” bars  512  and  508  are a set of web or shear plates  554 , with a first end of the plates  554  coupled to bar  506 , and a second end of the plate  554  coupled to the corner “B” bar  508 . Coupling the corner “C” bars  518  and  516  to the corner “D” bars  520  and  514  are a set of web or shear plates  550 , with a first end of the plates  550  coupled to bar  516 , and a second end of the plate  550  coupled to the corner bar  520 .  
         [0050]     All plates are welded to the flanges (the one or more corner bars) in locations that can provide the optimum strength, weight, and bulk for the structure  502 , with appropriate spacing  212  created between each individual plate for optimal curing of later injected material. Each set of plates is oriented normal to its adjacent set, and each plate within each set is coupled to its respective two flanges, aligned axially or longitudinally along a single plane passing through the axial length of both flanges. A completely fabricated structure  502  may be placed inside a mold to be encapsulated within body  204  using injection-molding techniques described above in relation to  FIGS. 3A  to  3 H.  FIG. 5D  is an exemplary illustration of the beam  500  in the cross-sectional view along the axial length indicated by the reference  532 , and the plan or top view  534  taken along the axial length of the beam.  
         [0051]      FIGS. 6A  to  6 D are exemplary illustration of a second type of a four sided frame structure  602  in accordance with the present invention, with a substantially trapezoidal cross-section. Although not illustrated for brevity, it should be understood that like the previously illustrated I-beam frames  302  in all the  FIGS. 3A  to  3 H, the four sided frame structure  602  may also be comprised of different flanges and web or shear plate constructions that vary in number, size, and shapes, similar to those illustrated in  FIGS. 3A  to  3 H. In fact, each of the four sides of the quadrilateral structure  602  may be constructed by using any combinations and or permutations of the above-described structure  302 . The four sided structure  602  has the added advantage in that it is a hybrid between a substantially square frame and a triangular square, providing both strength and high stability for the beam  600 . However, the exterior body  204  dimensions remain the same, commensurate with industry standard practices where the beams are to be used.  
         [0052]     As  FIGS. 6A  to  6 C illustrate, the tie  600  is comprised of a structure  602  that has a quadrilateral cross section, encapsulated in body  204 . The quadrilateral structure  602  includes two upper and two lower flanges, each of which may be comprised of one or more axial or longitudinal bars. As best illustrated in  FIG. 6B , the four corners A, B, C, and D of the quadrilateral beam structure  602  include an axial or longitudinal bar  604  that forms the first corner A, a second axial or longitudinal bar  608  that forms the second corner B, a third axial or longitudinal bar  612  that forms the third corner C, and finally a fourth bar  614  that forms the last or the fourth corner D of the quadrilateral frame  602 .  
         [0053]     Coupling the corner “A” bar  604  to the corner “D” bar  614  are a first set laterally inclined web or shear plates  610  and  211 , and coupling the corner “B” bar  608  to the corner “C” bar  612  are a second set of laterally inclined web or shear plates  652  and  211 . The respective first and second set of laterally inclined web or shear plates  610  and  652  (including the two sets of plates  211  within each respective set of plates  610  and  652 ) have opposing slopes, and each plate within its respective set is coupled so to allow a space  212  between the plates. The corner “A” bar  604  is further coupled to the corner “B” bar  608  by a third set of web or shear plates  654 , and the corner “C” bar  612  is coupled to the corner “D” bar  614  by a fourth set of web or shear plates  650 . The respective third and fourth set of web or shear plates  654  and  650  are oriented substantially parallel to one another, and each plate within its respective set is coupled so to allow a space  212  between the plates. All plates are welded to the flanges (the one or more corner bars) in locations that can provide the optimum strength, weight, and bulk for the structure  602 , with appropriate spacing  212  created between each individual plate for optimal curing of later injected material.  
         [0054]     A completely fabricated structure  602  may be placed inside a mold to be encapsulated within body  204  using injection-molding techniques described above in relation to  FIGS. 3A  to  3 H.  FIG. 6D  is an exemplary illustration of the beam  600  in the cross-sectional view along the axial length indicated by the reference  632 , and the plan or top view  634  taken along the axial length of the beam.  
         [0055]     Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, although weldable steel or steel alloy is mentioned in the description as the preferred material used for making the frames, any material that can meet the strength requirement characteristics appropriate for use within a heavy load-bearing environment may be used. That is, any material having the appropriate characteristics to withstand the tensile, compression, shear, and torsion forces exerted by a heavy load may be used for the frames. Further, the parts (if more than one used to construct a frame, such as a web plate and two bars) of any frame that are welded, may be coupled by other mechanisms or technologies that can provide appropriate bonding strength. The material is limited to steel or steel alloy, but can be a structural plastic, and the bonding is not limited to welding. In addition, the parts of any frame need not be made from the same material. The application of the present invention should not be limited to the railroad industry, but can be applied to any field for which a need exists, including their use underneath roads or support bridges, for monorails, street cars and the like. The various reinforcement structures can be made of multiple components joined together such as by welding or an adhesive, or can be formed as a single component such as by molding.  
         [0056]     Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.  
         [0057]     All features disclosed in the specification, including the claims, abstracts, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.  
         [0058]     Any element in a claim that does not explicitly state “means” for performing a specified function or “step” for performing a specified function, should not be interpreted as a “means” for “step” clause as specified in 35 U.S.C. §112.

Technology Classification (CPC): 4